Drilling apparatus with reduced exposure of cutters and methods of drilling

ABSTRACT

A rotary drilling apparatus and method for drilling subterranean formations, including a body being provided with at least one cutter thereon exhibiting reduced, or limited, exposure to the formation, so as to control the depth-of-cut of the at least one cutter, so as to control the volume of formation material cut per rotation of the drilling apparatus, as well as to control the amount of torque experienced by the drilling apparatus and an optionally associated bottomhole assembly regardless of the effective weight-on-bit are all disclosed. The exterior of the drilling apparatus may include a plurality of blade structures carrying at least one such cutter thereon and including a sufficient amount of bearing surface area to contact the formation so as to generally distribute an additional weight applied to the drilling apparatus against the bottom of the borehole without exceeding the compressive strength of the formation rock.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 11/214,524,filed Aug. 30, 2005, now U.S. Pat. No. 7,096,978 issued Aug. 29, 2006,which is a continuation of application Ser. No. 10/861,129, filed Jun.4, 2004, now U.S. Pat. No. 6,935,441, issued Aug. 30, 2005, which is acontinuation of application Ser. No. 10/266,534, filed Oct. 7, 2002, nowU.S. Pat. 6,779,613, issued Aug. 24, 2004, which is a continuation ofapplication Ser. No. 09/738,687, filed Dec. 15, 2000, now U.S. Pat.6,460,631, issued Oct. 8, 2002, which is a continuation-in-part ofapplication Ser. No. 09/383,228, filed Aug. 26, 1999, now U.S. Pat. No.6,298,930, issued Oct. 9, 2001, entitled Drill Bits with ControlledCutter Loading and Depth of Cut.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to rotary drag bits for drillingsubterranean formations and their operation. More specifically, thepresent invention relates to the design of such bits for optimumperformance in the context of controlling cutter loading anddepth-of-cut without generating an excessive amount of torque-on-bitshould the weight-on-bit be increased to a level which exceeds theoptimal weight-on-bit for the current rate-of-penetration of the bit.

2. State of the Art

Rotary drag bits employing polycrystalline diamond compact (PDC) cuttershave been employed for several decades. PDC cutters are typicallycomprised of a disc-shaped diamond “table” formed on and bonded underhigh-pressure and high-temperature conditions to a supporting substrate,such as cemented tungsten carbide (WC), although other configurationsare known in the art. Bits carrying PDC cutters, which for example, maybe brazed into pockets in the bit face, pockets in blades extending fromthe face, or mounted to studs inserted into the bit body, have provenvery effective in achieving high rates of penetration (ROP) in drillingsubterranean formations exhibiting low to medium compressive strengths.Recent improvements in the design of hydraulic flow regimes about theface of bits, cutter design, and drilling fluid formulation have reducedprior, notable tendencies of such bits to “ball” by increasing thevolume of formation material which may be cut before exceeding theability of the bit and its associated drilling fluid flow to clear theformation cuttings from the bit face.

Even in view of such improvements, however, PDC cutters still sufferfrom what might simply be termed “overloading” even at low weight-on-bit(WOB) applied to the drill string to which the bit carrying such cuttersis mounted, especially if aggressive cutting structures are employed.The relationship of torque to WOB may be employed as an indicator ofaggressivity for cutters, so the higher the torque to WOB ratio, themore aggressive the cutter. This problem is particularly significant inlow compressive strength formations where an unduly great depth of cut(DOC) may be achieved at extremely low WOB. The problem may also beaggravated by drill string bounce, wherein the elasticity of the drillstring may cause erratic application of WOB to the drill bit, withconsequent overloading. Moreover, operating PDC cutters at anexcessively high DOC may generate more formation cuttings than can beconsistently cleared from the bit face and back up the bore hole via thejunk slots on the face of the bit by even the aforementioned improved,state-of-the-art bit hydraulics, leading to the aforementioned bitballing phenomenon.

Another, separate problem involves drilling from a zone or stratum ofhigher formation compressive strength to a “softer” zone of lowerstrength. As the bit drills into the softer formation without changingthe applied WOB (or before the WOB can be changed by the directionaldriller), the penetration of the PDC cutters, and thus the resultingtorque on the bit (TOB), increase almost instantaneously and by asubstantial magnitude. The abruptly higher torque, in turn, may causedamage to the cutters and/or the bit body itself. In directionaldrilling, such a change causes the tool face orientation of thedirectional (measuring-while-drilling, or MWD, or a steering tool)assembly to fluctuate, making it more difficult for the directionaldriller to follow the planned directional path for the bit. Thus, it maybe necessary for the directional driller to back off the bit from thebottom of the borehole to reset or reorient the tool face. In addition,a downhole motor, such as drilling fluid-driven Moineau-type motorscommonly employed in directional drilling operations in combination witha steerable bottomhole assembly, may completely stall under a suddentorque increase. That is, the bit may stop rotating thereby stopping thedrilling operation and again necessitating backing off the bit from theborehole bottom to re-establish drilling fluid flow and motor output.Such interruptions in the drilling of a well can be time consuming andquite costly.

Numerous attempts using various approaches have been made over the yearsto protect the integrity of diamond cutters and their mountingstructures and to limit cutter penetration into a formation beingdrilled. For example, from a period even before the advent of commercialuse of PDC cutters, U.S. Pat. No. 3,709,308 discloses the use oftrailing, round natural diamonds on the bit body to limit thepenetration of cubic diamonds employed to cut a formation. U.S. Pat. No.4,351,401 discloses the use of surface set natural diamonds at or nearthe gage of the bit as penetration limiters to control the depth-of-cutof PDC cutters on the bit face. The following other patents disclose theuse of a variety of structures immediately trailing PDC cutters (withrespect to the intended direction of bit rotation) to protect thecutters or their mounting structures: U.S. Pat. Nos. 4,889,017;4,991,670; 5,244,039 and 5,303,785. U.S. Pat. No. 5,314,033 discloses,inter alia, the use of cooperating positive and negative or neutralbackrake cutters to limit penetration of the positive rake cutters intothe formation. Another approach to limiting cutting element penetrationis to employ structures or features on the bit body rotationallypreceding (rather than trailing) PDC cutters, as disclosed in U.S. Pat.Nos. 3,153,458; 4,554,986; 5,199,511 and 5,595,252.

In another context, that of so-called “anti-whirl” drilling structures,it has been asserted in U.S. Pat. 5,402,856 to one of the inventorsherein that a bearing surface aligned with a resultant radial forcegenerated by an anti-whirl under-reamer should be sized so that forceper area applied to the borehole sidewall will not exceed thecompressive strength of the formation being under-reamed. See also U.S.Pat. Nos. 4,982,802; 5,010,789; 5,042,596; 5,111,892 and 5,131,478.

While some of the foregoing patents recognize the desirability to limitcutter penetration, or DOC, or otherwise limit forces applied to aborehole surface, the disclosed approaches are somewhat generalized innature and fail to accommodate or implement an engineered approach toachieving a target ROP in combination with more stable, predictable bitperformance. Furthermore, the disclosed approaches do not provide a bitor method of drilling which is generally tolerant to being axiallyloaded with an amount of weight-on-bit over and in excess what would beoptimum for the current rate-of-penetration for the particular formationbeing drilled and which would not generate high amounts of potentiallybit-stopping or bit-damaging torque-on-bit, should the bit nonethelessbe subjected to such excessive amounts of weight-on-bit.

BRIEF SUMMARY OF THE INVENTION

The present invention addresses the foregoing needs by providing awell-reasoned, easily implementable bit design particularly suitable forPDC cutter-bearing drag bits, which bit design may be tailored tospecific formation compressive strengths or strength ranges to provideDOC control in terms of both maximum DOC and limitation of DOCvariability. As a result, continuously achievable ROP may be optimizedand torque controlled even under high WOB, while destructive loading ofthe PDC cutters is largely prevented.

The bit design of the present invention employs depth of cut control(DOCC) features, which reduce, or limit, the extent in which PDC cuttersor other types of cutters or cutting elements are exposed on the bitface, on bladed structures, or as otherwise positioned on the bit. TheDOCC features of the present invention provide substantial area on whichthe bit may ride while the PDC cutters of the bit are engaged with theformation to their design DOC, which may be defined as the distance thePDC cutters are effectively exposed below the DOCC features. Statedanother way, the cutter standoff is substantially controlled by theeffective amount of exposure of the cutters above the surface, orsurfaces, surrounding each cutter. Thus, by constructing the bit so asto limit the exposure of at least some of the cutters on the bit, suchlimited exposure of the cutters in combination with the bit providesample surface area to serve as a “bearing surface,” in which the bitrides as the cutters engage the formation at their respective design DOCenables a relatively greater DOC (and thus ROP for a given bitrotational speed) than with a conventional bit design without theadverse consequences usually attendant thereto. Therefore the DOCCfeatures of the present invention preclude a greater DOC than thatdesigned for by distributing the load attributable to WOB over asufficient surface area on the bit face, blades or other bit bodystructure contacting the formation face at the borehole bottom so thatthe compressive strength of the formation will not be exceeded by theDOCC features. As a result, the bit does not substantially indent, orfail, the formation rock.

Stated another way, the present invention limits the unit volume offormation material (rock) removed per bit rotation to prevent the bitfrom over-cutting the formation material and balling the bit or damagingthe cutters. If the bit is employed in a directional drilling operation,tool face loss or motor stalling is also avoided.

In one embodiment, a rotary drag bit preferably includes a plurality ofcircumferentially spaced blade structures extending along the leadingend or formation engaging portion of the bit generally from the coneregion approximate the longitudinal axis, or centerline, of the bit,upwardly to the gage region, or maximum drill diameter of the bit. Thebit further includes a plurality of superabrasive cutting elements, orcutters, such as PDC cutters, preferably disposed on radially outwardfacing surfaces of preferably each of the blade structures. Inaccordance with the DOCC aspect of the present invention, each cutterpositioned in at least the cone region of the bit, e.g., those cutterswhich are most radially proximate the longitudinal centerline and thusare generally positioned radially inward of a shoulder portion of thebit, are disposed in their respective blade structures in such a mannerthat each of such cutters is exposed only to a limited extent above theradially outwardly facing surface of the blade structures in which thecutters are associatively disposed. That is, each of such cuttersexhibit a limited amount of exposure generally perpendicular to theselected portion of the formation-facing surface, in which thesuperabrasive cutter is secured to control the effective depth-of-cut ofat least one superabrasive cutter into a formation when the bit isrotatingly engaging a formation, such as during drilling. By so limitingthe amount of exposure of such cutters by, for example, the cuttersbeing secured within and substantially encompassed by cutter-receivingpockets, or cavities, the DOC of such cutters into the formation iseffectively and individually controlled. Thus, regardless of the amountof WOB placed or applied on the bit, even if the WOB exceeds what wouldbe considered an optimum amount for the hardness of the formation beingdrilled and the ROP in which the drill bit is currently providing, theresulting torque, or TOB, will be controlled or modulated. Thus, becausesuch cutters have a reduced amount of exposure above the respectiveformation-facing surface in which it is installed, especially ascompared to prior art cutter installation arrangements, the resultantTOB generated by the bit will be limited to a maximum, acceptable value.This beneficial result is attributable to the DOCC features, orcharacteristics, of the present invention effectively preventing atleast a sufficient number of the total number of cutters fromover-engaging the formation and potentially causing the rotation of thebit to slow or stall due to an unacceptably high amount of torque beinggenerated. Furthermore, the DOCC features of the present invention areessentially unaffected by excessive amounts of WOB, as there willpreferably be a sufficient amount or size of bearing surface area devoidof cutters on at least the leading end of the bit in which the bit may“ride” upon the formation to inhibit or prevent a torque-induced bitstall from occurring.

Optionally, bits employing the DOCC aspects of the present invention mayhave reduced exposure cutters positioned radially more distant thanthose cutters proximate to the longitudinal centerline of the bit, suchas in the cone region. To elaborate, cutters having reduced exposure maybe positioned in other regions of a drill bit embodying the DOCC aspectsof the present invention. For example, reduced exposure cutterspositioned on the comparatively more radially distant nose, shoulder,flank, and gage portions of a drill bit will exhibit a limited amount ofcutter exposure generally perpendicular to the selected portion of theradially outwardly facing surface to which each of the reduced exposurecutters are respectively secured. Thus, the surfaces carrying andproximately surrounding each of the additional reduced exposure cutterswill be available to contribute to the total combined bearing surfacearea on which the bit will be able to ride upon the formation as therespective maximum depth-of-cut for each additional reduced exposurecutter is achieved depending upon the instant WOB and the hardness ofthe formation being drilled.

By providing DOCC features having a cumulative surface area sufficientto support a given WOB on a given rock formation, preferably withoutsubstantial indentation or failure of same, WOB may be dramaticallyincreased, if desired, over that usable in drilling with conventionalbits without the PDC cutters experiencing any additional effective WOBafter the DOCC features are in full contact with the formation. Thus,the PDC cutters are protected from damage and, equally significant, thePDC cutters are prevented from engaging the formation to a greater depthof cut and consequently generating excessive torque may stall a motor orcause loss of tool face orientation.

The ability to dramatically increase WOB without adversely affecting thePDC cutters also permits the use of WOB substantially above and beyondthe magnitude applicable without the adverse effects associated withconventional bits to maintain the bit in contact with the formation,reduce vibration and enhance the consistency and depth of cutterengagement with the formation. In addition, drill string, as well asdynamic axial effects, commonly termed “bounce” of the drill stringunder applied torque and WOB may be damped so as to maintain the designDOC for the PDC cutters. Again, in the context of directional drilling,this capability ensures maintenance of tool face and stall-freeoperation of an associated downhole motor driving the bit.

It is specifically contemplated that the DOCC features according to thepresent invention may be applied to coring bits as well as full boredrill bits. As used herein, the term “bit” encompasses core bits andother special purpose bits. Such usage may be, by way of example only,particularly beneficial when coring from a floating drilling rig, orplatform, where WOB is difficult to control because of surface waterwave-action-induced rig heave. When using the present invention, a WOBin excess of that normally required for coring may be applied to thedrill string to keep the core bit on bottom and maintain core integrityand orientation.

It is also specifically contemplated that the DOCC attributes of thepresent invention have particular utility in controlling andspecifically reducing torque required to rotate rotary drag bits as WOBis increased. While relative torque may be reduced in comparison to thatrequired by conventional bits for a given WOB by employing the DOCCfeatures at any radius or radii range from the bit centerline, variationin placement of DOCC features with respect to the bit centerline may bea useful technique for further limiting torque since the axial loadingon the bit from applied WOB is more heavily emphasized toward thecenterline and the frictional component of the torque is related to suchaxial loading. Accordingly, the present invention optionally includesproviding a bit in which the extent of exposure of the cutters vary withrespect to the cutters' respective positions on the face of the bit. Asan example, one or more of the cutters positioned in the cone, or theregion of the bit proximate the centerline of the bit, are exposed to afirst extent, or amount, to provide a first DOC and one or more cutterspositioned in the more radially distant nose and shoulder regions of thebit are exposed at a second extent, or amount, to provide a second DOC.Thus, a specifically engineered DOC profile may be incorporated into thedesign of a bit embodying the present invention to customize, or tailor,the bit's operational characteristics in order to achieve a maximum ROPwhile minimizing and/or modulating the TOB at the current WOB, even ifthe WOB is higher than what would otherwise be desired for the ROP andthe specific hardness of the formation then being drilled.

Furthermore, bits embodying the present invention may include bladestructures in which the extent of exposure of each cutter positioned oneach blade structure has a particular and optionally individually uniqueDOC, as well as individually selected and possibly unique effectivebackrake angles, thus resulting in each blade of the bit having apreselected DOC cross-sectional profile as taken longitudinally parallelto the centerline of the bit and taken radially to the outermost gageportion of each blade. Moreover, a bit incorporating the DOCC featuresof the present invention need not have cutters installed on, or carriedby, blade structures, as cutters having a limited amount of exposureperpendicular to the exterior of the bit in which each cutter isdisposed, may be incorporated on regions of bits in which no bladestructures are present. That is, bits incorporating the presentinvention may be completely devoid of blade structures entirely, suchas, for example, a coring bit.

A method of constructing a drill bit in accordance with the presentinvention is additionally disclosed herein. The method includesproviding at least a portion of the drill bit with at least one cuttingelement-accommodating pocket, or cavity, on a surface which willultimately face and engage a formation upon the drill bit being placedin operation. The method of constructing a bit for drilling subterraneanformations includes disposing within at least one cutter-receivingpocket a cutter exhibiting a limited amount of exposure perpendicular tothe formation-facing surface proximate the cutter upon the cutter beingsecured therein. Optionally, the formation-facing surface may be builtup by a hard facing, a weld, a weldment, or other material beingdisposed upon the surface surrounding the cutter so as to provide abearing surface of a sufficient size while also limiting the amount ofcutter exposure within a preselected range to effectively control thedepth of cut that the cutter may achieve upon a certain WOB beingexceeded and/or upon a formation of a particular compressive strengthbeing encountered.

A yet further option is to provide wear knots, or structures, formed ofa suitable material which extend outwardly and generally perpendicularlyfrom the face of the bit in general proximity of at least one or more ofthe reduced exposure cutters. Such wear knots may be positionedrotationally behind, or trailing, each provided reduced exposure cutterso as to augment the DOCC aspects provided by the bearing surfacerespectively carrying and proximately surrounding a significant portionof each reduced exposure cutter. Thus, the optional wear knots, or wearbosses, provide a bearing surface area in which the drill bit may rideon the formation upon the maximum DOC of that cutter being obtained forthe present formation hardness and then current WOB. Such wear knots, orbosses, may comprise hard facing material, structure provided whencasting or molding the bit body or, in the case of steel-bodied bits,may comprise weldments, structures secured to the bit body by methodsknown within the art of subterranean drill bit construction, or bysurface welds in the shape of one or more weld-beads or otherconfigurations or geometries.

A method of drilling a subterranean formation is further disclosed. Themethod for drilling includes engaging a formation with at least onecutter and preferably a plurality of cutters in which one or more of thecutters each exhibit a limited amount of exposure perpendicular to asurface in which each cutter is secured. In one embodiment, several ofthe plurality of limited exposure cutters are positioned on aformation-facing surface of at least one portion, or region, of at leastone blade structure, to render a cutter spacing and cutter exposureprofile for that blade and preferably for a plurality of blades whichwill enable the bit to engage the formation within a wide range of WOBwithout generating an excessive amount of TOB, even at elevated WOBs,for the instant ROP in which the bit is providing. The method furtherincludes an alternative embodiment in which the drilling is conductedwith primarily only the reduced exposure cutters engaging a relativelyhard formation within a selected range of WOB and upon a softerformation being encountered and/or an increased amount of WOB beingapplied, at least one bearing surface surrounding at least one reduced,or limited, exposure cutter, and preferably a plurality of sufficientlysized bearing surfaces respectively surrounding a plurality of reducedexposure cutters, contacts the formation and thus limits the DOC of eachreduced, or limited, exposure cutter while allowing the bit to ride onthe bearing surface, or bearing surfaces, against the formationregardless of the WOB being applied to the bit and without generating anunacceptably high, potentially bit damaging TOB for the current ROP.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a bottom elevation looking upward at the face of oneembodiment of a drill bit including the DOCC features according to theinvention;

FIG. 2 is a bottom elevation looking upward at the face of anotherembodiment of a drill bit including the DOCC features according to theinvention;

FIG. 2A is a side sectional elevation of the profile of the bit of FIG.2;

FIG. 3 is a graph depicting mathematically predicted torque versus WOBfor conventional bit designs employing cutters at different backrakesversus a similar bit according to the present invention;

FIG. 4 is a schematic side elevation, not to scale, comparing prior artplacement of a depth-of-cut limiting structure closely behind a cutterat the same radius, taken along a 360° rotational path, versus placementaccording to the present invention preceding the cutter and at the sameradius;

FIG. 5 is a schematic side elevation of a two-step DOCC feature andassociated trailing PDC cutter;

FIGS. 6A and 6B are, respectively, schematics of single-angle bearingsurface and multi-angle bearing surface DOCC feature;

FIGS. 7 and 7A are, respectively, a schematic side partial sectionalelevation of an embodiment of a pivotable DOCC feature and associatedtrailing PDC cutter, and an elevation looking forward at the pivotableDOCC feature from the location of the associated PDC cutter;

FIGS. 8 and 8A are, respectively, a schematic side partial sectionalelevation of an embodiment of a roller-type DOCC feature and associatedtrailing cutter, and a transverse partial cross-sectional view of themounting of the roller-type DOCC features to the bit;

FIGS. 9A-9D depict additional schematic partial sectional elevations offurther pivotable DOCC features according to the invention;

FIGS. 10A and 10B are schematic side partial sectional elevations ofvariations of a combination cutter carrier and DOCC features accordingto the present invention;

FIG. 11 is a frontal elevation of an annular channel-type DOCC featurein combination with associated trailing PDC cutters;

FIGS. 12 and 12A are, respectively, a schematic side partial sectionalelevation of a fluid bearing pad-type DOCC feature according to thepresent invention and an associated trailing PDC cutter and an elevationlooking upward at the bearing surface of the pad;

FIGS. 13A-13C are transverse sections of various cross-sectionalconfigurations for the DOCC features according to the invention;

FIG. 14A is a perspective view of the face of one embodiment of a drillbit having eight blade structures including reduced exposure cuttersdisposed on at least some of the blades in accordance with the presentinvention;

FIG. 14B is a bottom view of the face of the exemplary drill bit of FIG.14A;

FIG. 14C is a photographic bottom view of the face of another exemplarydrill bit embodying the present invention having six blade structuresand a different cutter profile than the cutter profile of the exemplarybit illustrated in FIGS. 14A and 14B;

FIG. 15A is a schematic side partial sectional view showing the cutterprofile and radial spacing of adjacently positioned cutters along asingle, representative blade of a drill bit embodying the presentinvention;

FIG. 15B is a schematic side partial sectional view showing the combinedcutter profile, including cutter-to-cutter overlap of the cutterspositioned along all the blades, as superimposed upon a single,representative blade;

FIG. 15C is a schematic side partial sectional view showing the extentof cutter exposure along the cutter profile as illustrated in FIGS. 15Aand 15B with the cutters removed for clarity and further shows arepresentative, optional wear knot, or wear cloud, profile;

FIG. 16 is an enlarged, isolated schematic side partial sectional viewillustrating an exemplary superimposed cutter profile having a relativelow amount of cutter overlap in accordance with the present invention;

FIG. 17 is an enlarged, isolated schematic side partial sectional viewillustrating an exemplary superimposed cutter profile having a relativehigh amount of cutter overlap in accordance with the present invention;

FIG. 18A is an isolated, schematic, frontal view of three representativecutters positioned in the cone region of a representative bladestructure of a representative bit, each cutter is exposed at apreselected amount so as to limit the DOC of the cutters, while alsoproviding individual kerf regions between cutters in the bearing surfaceof the blade in which the cutters are secured contributing to the bit'sability to ride, or rub, upon the formation when a bit embodying thepresent invention is in operation;

FIG. 18B is a schematic, partial side cross-sectional view of one of thecutters depicted in FIG. 18A as the cutter engages a relatively hardformation and/or engages a formation at a relatively low WOB, resultingin a first, less than maximum DOC;

FIG. 18C is a schematic, partial side cross-sectional view of the cutterdepicted in FIG. 18A as the cutter engages a relatively soft formationand/or engages a formation at relatively high WOB resulting in a second,essentially maximum DOC;

FIG. 19 is a graph depicting laboratory test results of Aggressivenessversus DOC for a representative prior art steerable bit (STR bit), aconventional, or standard, general purpose bit (STD bit) and twoexemplary bits embodying the present invention (RE-W and RE-S) as testedin a Carthage limestone formation at atmospheric pressure;

FIG. 20 is a graph depicting laboratory test results of WOB versus ROPfor the tested bits;

FIG. 21 is a graph depicting laboratory test results of TOB versus ROPfor the tested bits; and

FIG. 22 is a graph depicting laboratory test results of TOB versus WOBfor the tested bits.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 of the drawings depicts a rotary drag bit 10 looking upwardly atits face or leading end 12 as if the viewer were positioned at thebottom of a borehole. Bit 10 includes a plurality of PDC cutters 14bonded by their substrates (diamond tables and substrates not shownseparately for clarity), as by brazing, into pockets 16 in blades 18extending above the face 12, as is known in the art with respect to thefabrication of so-called “matrix” type bits. Such bits include a mass ofmetal powder, such as tungsten carbide, infiltrated with a molten,subsequently hardenable binder, such as a copper-based alloy. It shouldbe understood, however, that the present invention is not limited tomatrix-type bits, and that steel body bits and bits of other manufacturemay also be configured according to the present invention.

Fluid courses 20 lie between blades 18 and are provided with drillingfluid by nozzles 22 secured in nozzle orifices 24, orifices 24 being atthe end of passages leading from a plenum extending into the bit bodyfrom a tubular shank at the upper, or trailing, end of the bit (see FIG.2A in conjunction with the accompanying text for a description of thesefeatures). Fluid courses 20 extend to junk slots 26 extending upwardlyalong the side of bit 10 between blades 18. Gage pads 19 compriselongitudinally upward extensions of blades 18 and may havewear-resistant inserts or coatings on radially outer surfaces 21 thereofas known in the art. Formation cuttings are swept away from PDC cutters14 by drilling fluid F emanating from nozzle orifices 24, the drillingfluid F moving generally radially outwardly through fluid courses 20 andthen upwardly through junk slots 26 to an annulus between the drillstring from which the bit 10 is suspended and on to the surface.

Referring again to FIG. 1, a plurality of the DOCC features, eachcomprising an arcuate bearing segment 30 a through 30 f, reside on, andin some instances bridge between, blades 18. Specifically, bearingsegments 30 b and 30 e each reside partially on an adjacent blade 18 andextend therebetween. The arcuate bearing segments 30 a through 30 f,each of which lies along substantially the same radius from the bitcenterline as a PDC cutter 14 rotationally trailing that bearing segment30, together provide sufficient surface area to withstand the axial orlongitudinal WOB without exceeding the compressive strength of theformation being drilled, so that the rock does not indent or fail andthe penetration of PDC cutters 14 into the rock is substantiallycontrolled. As can be seen in FIG. 1, wear-resistant elements or inserts32, in the form of tungsten carbide bricks or discs, diamond grit,diamond film, natural or synthetic diamond (PDC or TSP), or cubic boronnitride, may be added to the exterior bearing surfaces of bearingsegments 30 to reduce the abrasive wear thereof by contact with theformation under WOB as the bit 10 rotates under applied torque. In lieuof inserts, the bearing surfaces may be comprised of, or completelycovered with, a wear-resistant material. The significance of wearcharacteristics of the DOCC features will be explained in more detailbelow.

FIGS. 2 and 2A depict another embodiment of a rotary drill bit 100according to the present invention. For clarity, features and elementsin FIGS. 2 and 2A corresponding to those identified with respect to bit10 of FIG. 1 are identified with the same reference numerals. FIG. 2depicts a rotary drill bit 100 looking upwardly at its face 12 as if theviewer were positioned at the bottom of a borehole. Bit 100 alsoincludes a plurality of PDC cutters 14 bonded by their substrates(diamond tables and substrates not shown separately for clarity), as bybrazing, into pockets 16 in blades 18 extending above the face 12 of bit100.

Fluid courses 20 lie between blades 18 and are provided with drillingfluid F by nozzles 22 secured in nozzle orifices 24, orifices 24 beingat the end of passages 36 leading from a plenum 38 extending into bitbody 40 from a tubular shank 42 threaded (not shown) on its exteriorsurface 44 as known in the art at the upper end of the bit 100 (see FIG.2A). Fluid courses 20 extend to junk slots 26 extending upwardly alongthe side of bit 10 between blades 18. Gage pads 19 compriselongitudinally upward extensions of blades 18 and may havewear-resistant inserts or coatings on radially outer surfaces 21 thereofas known in the art.

Referring again to FIG. 2, a plurality of the DOCC features, eachcomprising an arcuate bearing segment 30 a through 30 f, reside on, andin some instances bridge between, blades 18. Specifically, bearing 30 band 30 e each reside partially on an adjacent blade 18 and extendtherebetween. The arcuate bearing segments 30 a through 30 f, each ofwhich lies substantially along the same radius from the bit centerlineas a PDC cutter 14 rotationally trailing that bearing segment 30,together provide sufficient surface area to withstand the axial orlongitudinal WOB without exceeding the compressive strength of theformation being drilled, so that the rock does not unduly indent or failand the penetration of PDC cutters 14 into the rock is substantiallycontrolled.

By way of example only, the total DOCC features surface area for an8.5-inch diameter bit generally configured as shown in FIGS. 1 and 2 maybe about 12 square inches. If, for example, the unconfined compressivestrength of a relatively soft formation to be drilled by either bit 10or 100 is 2,000 pounds per square inch (psi), then at least about 24,000lbs. WOB may be applied without failing or indenting the formation. SuchWOB is far in excess of the WOB which may normally be applied to a bitin such formations (for example, as little as 1,000 to 3,000 lbs., up toabout 5,000 lbs.) without incurring bit balling from excessive DOC andthe consequent cuttings volume which overwhelms the bit's hydraulicability to clear them. In harder formations, with, for example, 20,000to 40,000 psi compressive strengths, the total DOCC features surfacearea may be significantly reduced while still accommodating substantialWOB applied to keep the bit firmly on the borehole bottom. When older,less sophisticated, drill rigs are employed or during directionaldrilling, both of which render it difficult to control WOB with anysubstantial precision, the ability to overload WOB without adverseconsequences further distinguishes the superior performance of bitsembodying the present invention. It should be noted at this juncturethat the use of an unconfined compressive strength of formation rockprovides a significant margin for calculation of the required bearingarea of the DOCC features for a bit, as the in situ, confined,compressive strength of a subterranean formation being drilled issubstantially higher. Thus, if desired, confined compressive strengthvalues of selected formations may be employed in designing the totalDOCC features as well as the total bearing area of a bit to yield asmaller required area, but which still advisedly provides for anadequate “margin” of excess bearing area in recognition of variations incontinued compressive strengths of the formation to preclude substantialindentation and failure of the formation downhole.

While bit 100 is notably similar to bit 10, the viewer will recognizeand appreciate that wear inserts 32 are omitted from bearing segments 30a through 30 f on bit 100, such an arrangement being suitable for lessabrasive formations where wear is of lesser concern and the tungstencarbide of the bit matrix (or applied hard facing in the case of a steelbody bit) is sufficient to resist abrasive wear for a desired life ofthe bit. As shown in FIG. 13A, the DOCC features (bearing segments 30)of either bit 10 or bit 100, or of any bit according to the invention,may be of arcuate cross-section, taken transverse to the arc followed asthe bit rotates, to provide an arcuate bearing surface 31 a mimickingthe cutting edge arc of an unworn, associated PDC cutter following aDOCC feature. Alternatively, as shown in FIG. 13B, a DOCC feature(bearing segment 30) may exhibit a flat bearing surface 31 f to theformation, or may be otherwise configured. It is also contemplated, asshown in FIG. 13C, that a DOCC feature (bearing segment 30) may becross-sectionally configured and comprised of a material so as tointentionally and relatively quickly (in comparison to the wear rate ofa PDC cutter) wear from a smaller initial bearing surface 31 i providinga relatively small DOC₁ with respect to the point or line of contact Cwith the formation traveled by the cutting edge of a trailing,associated PDC cutter while drilling a first, hard formation interval toa larger, secondary bearing surface 31 s, which also provides a muchsmaller DOC₂ for a second, lower, much softer (and lower compressivestrength) formation interval. Alternatively, the head 33 of the DOCCstructure (bearing segment 30) may be made controllably shearable fromthe base 35 (as with frangible connections like a shear pin, one shearpin 37 shown in broken lines).

For reference purposes, bits 10 and 100 as illustrated, may be said tobe symmetrical or concentric about their centerlines or longitudinalaxes L, although this is not necessarily a requirement of the invention.

Both bits 10 and 100 are unconventional in comparison to state of theart bits in that PDC cutters 14 on bits 10 and 100 are disposed at farlesser backrakes, in the range of, for example, 7° to 15° with respectto the intended direction of rotation generally perpendicular to thesurface of the formation being engaged. In comparison, many conventionalbits are equipped with cutters at a 30° backrake and a 20° backrake isregarded as somewhat “aggressive” in the art. The presence of the DOCCfeature permits the use of substantially more aggressive backrakes, asthe DOCC features preclude the aggressively raked PDC cutters frompenetrating the formation to too great a depth, as would be the case ina bit without the DOCC features.

In the cases of both bit 10 and bit 100, the rotationally leading DOCCfeatures (bearing segments 30) are configured and placed tosubstantially exactly match the pattern drilled in the bottom of theborehole when drilling at an ROP of 100 feet per hour (fph) at 120rotations per minute (rpm) of the bit. This results in a DOC of about0.166 inch per revolution. Due to the presence of the DOCC features(bearing segments 30), after sufficient WOB has been applied to drill100 fph, any additional WOB is transferred from the bit body 40 of thebit 10 or 100 through the DOCC features to the formation. Thus, the PDCcutters 14 are not exposed to any substantial additional weight, unlessand until a WOB sufficient to fail the formation being drilled would beapplied, which application may be substantially controlled by thedriller, since the DOCC features may be engineered to provide a largemargin of error with respect to any given sequence of formations whichmight be encountered when drilling an interval.

As a further consequence of the present invention, the DOCC featureswould, as noted above, preclude PDC cutters 14 from excessivelypenetrating or “gouging” the formation, a major advantage when drillingwith a downhole motor where it is often difficult to control WOB and WOBinducing, such excessive penetration can result in the motor stalling,with consequent loss of tool face and possible damage to motorcomponents, as well as to the bit itself. While the addition of WOBbeyond that required to achieve the desired ROP will require additionaltorque to rotate the bit due to frictional resistance to rotation of theDOCC features over the formation, such additional torque is a lessercomponent of the overall torque.

The benefit of DOCC features in controlling torque can readily beappreciated by a review of FIG. 3 of the drawings, which is amathematical model of performance of a 3¾-inch diameter, four-bladed,Hughes Christensen R324XL PDC bit showing various torque versus WOBcurves for varying cutter backrakes in drilling Mancos shale. Curve Arepresents the bit with a 10° cutter backrake, curve B, the bit with a20° cutter backrake, curve C, the bit with a 30° cutter backrake, andcurve D, the bit using cutters disposed at a 20° backrake and includingthe DOCC features according to the present invention. The model assumesa bit design according to the invention for an ROP of 50 fph at 100 rpm,which provides 0.1 inch per revolution penetration of a formation beingdrilled. As can readily be seen, regardless of cutter backrake, curves Athrough C clearly indicate that, absent the DOCC features according tothe present invention, required torque on the bit continues to increasecontinuously and substantially linearly with applied WOB, regardless ofhow much WOB is applied. On the other hand, curve D indicates that,after WOB approaches about 8,000 lbs. on the bit, including the DOCCfeatures, the torque curve flattens significantly and increases in asubstantially linear manner only slightly from about 670 ft-lb. to justover 800 ft-lb. even as WOB approaches 25,000 lbs. As noted above, thisrelatively small increase in the torque after the DOCC features engagethe formation is frictionally related, and is also somewhat predictable.As graphically depicted in FIG. 3, this additional torque load increasessubstantially linearly as a function of WOB times the coefficient offriction between the bit and the formation.

Referring now to FIG. 4 (which is not to scale) of the drawings, afurther appreciation of the operation and benefits of the DOCC featuresaccording to the present invention may be obtained. Assuming a bitdesigned for an ROP of 120 fph at 120 rpm, this requires an average DOCof 0.20 inch. The DOCC features or DOC limiters would thus be designedto first contact the subterranean formation surface FS to provide a 0.20inch DOC. It is assumed for the purposes of FIG. 4 that DOCC features orDOC limiters are sized so that compressive strength of the formationbeing drilled is not exceeded under applied WOB. As noted previously,the compressive strength of concern would typically be the in situcompressive strength of the formation rock resident in the formationbeing drilled (plus some safety factor), rather than unconfinedcompressive strength of a rock sample. In FIG. 4, an exemplary PDCcutter 14 is shown, for convenience, moving linearly right to left onthe page. One complete revolution of the bit 10 or 100 on which PDCcutter 14 is mounted has been “unscrolled” and laid out flat in FIG. 4.Thus, as shown, PDC cutter 14 has progressed downwardly (i.e., along thelongitudinal axis of the bit 10 or 100 on which it is mounted) 0.20 inchin 360° of rotation of the bit 10 or 100. As shown in FIG. 4, astructure or element to be used as a DOC limiter 50 is locatedconventionally, closely rotationally “behind” PDC cutter 14, as only22.5° behind PDC cutter 14, the outermost tip 50 a must be recessedupwardly 0.0125 inch (0.20 inch DOC×22.5°/360°) from the outermost tip14 a of PDC cutter 14 to achieve an initial 0.20 inch DOC. However, whenDOC limiter 50 wears during drilling, for example, by a mere 0.010 inchrelative to the tip 14 a of PDC cutter 14, the vertical offset distancebetween the tip 50 a of DOC limiter 50 and tip 14 a of PDC cutter 14 isincreased to 0.0225 inch. Thus, DOC will be substantially increased, infact, almost doubled, to 0.36 inch. Potential ROP would consequentlyequal 216 fph due to the increase in vertical standoff provided to PDCcutter 14 by worn DOC limiter 50, but the DOC increase may damage PDCcutter 14 or ball the bit 10 or 100 by generating a volume of formationcuttings which overwhelms the bit's ability to clear them hydraulically.Similarly, if PDC cutter tip 14 a wore at a relatively faster rate thanDOC limiter 50 by, for example, 0.010 inch, the vertical offset distanceis decreased to 0.0025 inch, DOC is reduced to 0.04 inch and ROP to 24fph. Thus, excessive wear or vertical misplacement of either PDC cutter14 or DOC limiter 50 to the other may result in a wide range of possibleROPs for a given rotational speed. On the other hand, if an exemplaryDOCC feature 60 is placed, according to the present invention, 45°rotationally in front of (or 315° rotationally behind) PDC cutter tip 14a, the outermost tip 60 a would initially be recessed upwardly 0.175inch (0.20 inch DOC×315°/360°) relative to PDC cutter tip 14 a toprovide the initial 0.20 inch DOC. FIG. 4 shows the same DOCC feature 60twice, both rotationally in front of and behind PDC cutter 14, forclarity, it being, of course, understood that the path of PDC cutter 14is circular throughout a 360° arc in accordance with rotation of bit 10or 100. When DOCC feature 60 wears 0.010 inch relative to PDC cutter tip14 a, the vertical offset distance between tip 60 a of DOCC feature 60and tip 14 a of PDC cutter 14 is only increased from 0.175 inch to 0.185inch. However, due to the placement of DOCC feature 60 relative to PDCcutter 14, DOC will be only slightly increased to about 0.211 inch. As aconsequence, ROP would only increase to about 127 fph. Likewise, if PDCcutter 14 wears 0.010 inch relative to DOCC feature 60, vertical offsetof DOCC feature 60 is only reduced to 0.165 inch and DOC is only reducedto about 0.189 inch, with an attendant ROP of about 113 fph. Thus, itcan readily be seen how rotational placement of a DOCC feature cansignificantly affect ROP as the limiter or the cutter wears with respectto the other, or if one such component has been misplaced or incorrectlysized to protrude incorrectly even slightly upwardly or downwardly ofits ideal, or “design,” position relative to the other, associatedcomponent when the bit is fabricated. Similarly, mismatches in wearbetween a cutter and a cutter-trailing DOC limiter are magnified in theprior art, while being significantly reduced when DOCC features aresized and placed in cutter-leading positions according to the presentinvention are employed. Further, if a DOC limiter trailing, rather thanleading, a given cutter is employed, it will be appreciated that shockor impact loading of the cutter is more probable as, by the time the DOClimiter contacts the formation, the cutter tip will have alreadycontacted the formation. Leading DOCC features on the other hand, bybeing located in advance of a given cutter along the downward helicalpath, the cutter travels as it cuts the formation and the bit advancesalong its longitudinal axis, tend to engage the formation before thecutter. The terms “leading” and “trailing” the cutter may be easilyunderstood as being preferably respectively associated with DOCCfeatures positioned up to 180° rotationally preceding a cutter versusDOCC features positioned up to 180° rotationally trailing a cutter.While some portion of, for example, an elongated, arcuate leading DOCCfeature according to the present invention may extend so farrotationally forward of an associated cutter so as to approach atrailing position, the substantial majority of the arcuate length ofsuch a DOCC feature would preferably reside in a leading position. Asmay be appreciated by further reference to FIGS. 1 and 2, there may be asignificant rotational spacing between a PDC cutter 14 and an associatedbearing segment 30 of a DOCC feature, as across a fluid course 20 andits associated junk slot 26, while still rotationally leading the PDCcutter 14. More preferably, at least some portion of a DOCC featureaccording to the invention will lie within about 90° rotationallypreceding the face of an associated cutter.

One might question why limitation of ROP would be desirable, as bitsaccording to the present invention using DOCC features may not, in fact,drill at as great an ROP as conventional bits not so equipped. However,as noted above, by using DOCC features to achieve a predictable andsubstantially sustainable DOC in conjunction with a known ability of abit's hydraulics to clear formation cuttings from the bit at a givenmaximum volumetric rate, a sustainable (rather than only peak) maximumROP may be achieved without the bit balling and with reduced cutter wearand substantial elimination of cutter damage and breakage from excessiveDOC, as well as impact-induced damage and breakage. Motor stalling andloss of tool face may also be eliminated. In soft or ultra-softformations very susceptible to balling, limiting the unit volume of rockremoved from the formation per unit time prevents a bit from “overcutting” the formation. In harder formations, the ability to applyadditional WOB in excess of what is needed to achieve a design DOC forthe bit may be used to suppress unwanted vibration normally induced bythe PDC cutters and their cutting action, as well as unwanted drillstring vibration in the form of bounce, manifested on the bit by anexcessive DOC. In such harder formations, the DOCC features may also becharacterized as “load arresters” used in conjunction with “excess” WOBto protect the PDC cutters from vibration-induced damage, the DOCCfeatures again being sized so that the compressive strength of theformation is not exceeded. In harder formations, the ability to damp outvibrations and bounce by maintaining the bit in constant contact withthe formation is highly beneficial in terms of bit stability andlongevity, while in steerable applications the invention precludes lossof tool face.

FIG. 5 depicts one exemplary variation of a DOCC feature according tothe present invention, which may be termed a “stepped” DOCC feature 130comprising an elongated, arcuate bearing segment. Such a configuration,shown for purposes of illustration preceding a PDC cutter 14 on a bit100 (by way of example only), includes a lower, rotationally leadingfirst step 132 and a higher, rotationally trailing second step 134. Astip 14 a of PDC cutter 14 follows its downward helical path generallyindicated by line 140 (the path, as with FIG. 4, being unscrolled on thepage), the surface area of first step 132 may be used to limit DOC in aharder formation with a greater compressive strength, the bit “riding”high on the formation with PDC cutter 14 taking a minimal DOC₁ in theformation surface, shown by the lower dashed line. However, as bit 100enters a much softer formation with a far lesser compressive strength,the surface area of first step 132 will be insufficient to preventindentation and failure of the formation, and so first step 132 willindent the formation until the surface of second step 134 encounters theformation material, increasing DOC by PDC cutter 14. At that point, thetotal surface area of first and second steps 132 and 134 (in combinationwith other first and second steps respectively associated with other PDCcutters 14) will be sufficient to prevent further indentation of theformation and the deeper DOC₂ in the surface of the softer formation(shown by the upper dashed line) will be maintained until the bit 100once again encounters a harder formation. When this occurs, the bit 100will ride up on the first step 132, which will take any impact from theencounter before PDC cutter 14 encounters the formation, and the DOCwill be reduced to its previous DOC level, avoiding excessive torque andmotor stalling.

As shown in FIGS. 1 and 2, one or more DOCC features of a bit accordingto an invention may comprise elongated arcuate bearing segments 30disposed at substantially the same radius about the bit longitudinalaxis or centerline as a cutter preceded by that DOCC feature. In such aninstance, and as depicted in FIG. 6A with exemplary arcuate bearingsegment 30 unscrolled to lie flat on the page, it is preferred that theouter bearing surface S of a segment 30 be sloped at an angle α to aplane P transverse to the centerline L of the bit substantially the sameas the angle β (of the helical path 140) traveled by associated PDCcutter 14 as the bit drills the borehole. By so orienting the outerbearing surface S, the full potential surface, or bearing area ofbearing segment 30 contacts and remains in contact with the formation asthe PDC cutter 14 rotates. As shown in FIG. 6B, the outer surface S ofan arcuate segment 30 may also be sloped at a variable angle toaccommodate maximum and minimum design ROP for a bit. Thus, if a bit isdesigned to drill between 110 and 130 fph, the rotationally leadingportion LS of surface S may be at one, relatively shallower angle γ,while the rotationally trailing portion TS of surface S (all of surfaceS still rotationally leading PDC cutter 14) may be at another,relatively steeper angle δ, (both angles shown in exaggerated magnitudefor clarity) the remainder of surface S gradually transitioning in anangle therebetween. In this manner, and since DOC must necessarilyincrease for ROP to increase, given a substantially constant rotationalspeed, at a first, shallower helix angle 140 a corresponding to a lowerROP, the leading portion LS of surface S will be in contact with theformation being drilled, while at a higher ROP the helix angle willsteepen, as shown (exaggerated for clarity) by comparatively steeperhelix angle 140 b and leading portion LS will no longer contact theformation, the contact area being transitioned to more steeply angledtrailing portion TS. Of course, at an ROP intermediate the upper andlower limits of the design range, a portion of surface S intermediateleading portion LS and trailing portion TS (or portions of both LS andTS) would act as the bearing surface. A configuration as shown in FIG.6B is readily suitable for high compressive strength formations atvarying ROPs within a design range, since bearing surface arearequirements for the DOCC features are nominal. For bits used indrilling softer formations, it may be necessary to provide excesssurface area for each DOCC feature to prevent formation failure andindentation, as only a portion of each DOCC feature will be in contactwith the formation at any one time when drilling over a design range ofROPs. Conversely, for bits used in drilling harder formations, providingexcess surface area for each DOCC feature to prevent formation failureand indentation may not be necessary as the respective portions of eachDOCC feature may, when taken in combination, provide enough totalbearing surface area, or total size, for the bit to ride on theformation over a design range of ROPs.

Another consideration in the design of bits according to the presentinvention is the abrasivity of the formation being drilled, and relativewear rates of the DOCC features and the PDC cutters. In non-abrasiveformations this is not of major concern, as neither the DOCC feature northe PDC cutter will wear appreciably. However, in more abrasiveformations, it may be necessary to provide wear inserts 32 (see FIG. 1)or otherwise protect the DOCC features against excessive (i.e.,premature) wear in relation to the cutters with which they areassociated to prevent reduction in DOC. For example, if the bit is amatrix-type bit, a layer of diamond grit may be embedded in the outersurfaces of the DOCC features. Alternatively, pre-formed cementedtungsten carbide slugs cast into the bit face may be used as DOCCfeatures. A diamond film may be formed on selected portions of the bitface using known chemical vapor deposition techniques as known in theart, or diamond films formed on substrates which are then cast into orbrazed or otherwise bonded to the bit body. Natural diamonds, thermallystable PDCs (commonly termed TSPs) or even PDCs with faces thereonsubstantially parallel to the helix angle of the cutter path (so thatwhat would normally be the cutting face of the PDC acts as a bearingsurface), or cubic boron nitride structures similar to theaforementioned diamond structures may also be employed on, or as,bearing surfaces of the DOCC features, as desired or required, forexample when drilling in limestones and dolomites. In order to reducefrictional forces between a DOCC bearing surface and the formation, avery low roughness, so-called “polished” diamond surface may be employedin accordance with U.S. Pat. Nos. 5,447,208 and 5,653,300, assigned tothe assignee of the present invention and hereby incorporated herein bythis reference. Ideally, and taking into account wear of the diamondtable and supporting substrate in comparison to wear of the DOCCfeatures, the wear characteristics and volumes of materials taking thewear for the DOCC features may be adjusted so that the wear rate of theDOCC features may be substantially matched to the wear rate of the PDCcutters to maintain a substantially constant DOC. This approach willresult in the ability to use the PDC cutter to its maximum potentiallife. It is, of course, understood that the DOCC features may beconfigured as abbreviated “knots,” “bosses,” or large “mesas,” as wellas the aforementioned arcuate segments or may be of any otherconfiguration suitable for the formation to be drilled to preventfailure thereof by the DOCC features under expected or planned WOB.

As an alternative to a fixed, or passive, DOCC feature, it is alsocontemplated that active DOCC features or bearing segments may beemployed to various ends. For example, rollers may be disposed in frontof the cutters to provide reduced-friction DOCC features, or a fluidbearing comprising an aperture surrounded by a pad or mesa on the bitface may be employed to provide a standoff for the cutters withattendant low friction. Movable DOCC features, for example pivotablestructures, might also be used to accommodate variations in ROP within agiven range by tilting the bearing surfaces of the DOCC features so thatthe surfaces are oriented at the same angle as the helical path of theassociated cutters.

Referring now to FIGS. 7 though 12 of the drawings, various DOCCfeatures (which may also be referred to as bearing segments) accordingto the invention are disclosed.

Referring to FIGS. 7 and 7A, exemplary bit 150 having PDC cutter 14secured thereto rotationally trailing fluid course 20 includes pivotableDOCC feature 160 comprised of an arcuate-surfaced body 162 (which maycomprise a hemisphere for rotation about several axes or merely anarcuate surface extending transverse to the plane of the page forrotation about an axis transverse to the page) secured in socket 164 andhaving an optional wear-resistant feature 166 on the bearing surface 168thereof. Wear-resistant feature 166 may merely be an exposed portion ofthe material of body 162 if the latter is formed of, for example, WC.Alternatively, wear-resistant feature 166 may comprise a WC tip, insertor cladding on bearing surface 168 of body 162, diamond grit embedded inbody 162 at bearing surface 168, or a synthetic or natural diamondsurface treatment of bearing surface 168, including specifically andwithout limitation, a diamond film deposited thereon or bonded thereto.It should be noted that the area of the bearing surface 168 of the DOCCfeature 160 which will ride on the formation being drilled, as well asthe DOC for PDC cutter 14, may be easily adjusted for a given bit designby using bodies 162 exhibiting different exposures (heights) of thebearing surface 168 and different widths, lengths or cross-sectionalconfigurations, all as shown in broken lines. Thus, different formationcompressive strengths may be accommodated. The use of a pivotable DOCCfeature 160 permits the DOCC feature to automatically adjust todifferent ROPs within a given range of cutter helix angles. While DOCmay be affected by pivoting of the DOCC feature 160, variation within agiven range of ROPs will usually be nominal.

FIGS. 8 and 8A depict exemplary bit 150 having PDC cutter 14 securedthereto rotationally trailing fluid course 20, wherein bit 150 in thisinstance includes DOCC feature 170 including roller 172 rotationallymounted by shaft 174 to bearings 176 carried by bit 150 on each side ofcavity 178 in which roller 172 is partially received. In thisembodiment, it should be noted that the exposure and bearing surfacearea of DOCC feature 170 may be easily adjusted for a given bit designby using different diameter rollers 172 exhibiting different widthsand/or cross-sectional configurations.

FIGS. 9A, 9B, 9C and 9D respectively depict alternative pivotable DOCCfeatures 190, 200, 210 and 220. DOCC feature 190 includes a head 192partially received in a cavity 194 in a bit 150 and mounted through aball and socket connection 196 to a stud 180 press-fit into aperture 198at the top of cavity 194. DOCC feature 200, wherein elements similar tothose of DOCC feature 190 are identified by the same reference numerals,is a variation of DOCC feature 190. DOCC feature 210 employs a head 212,which is partially received in a cavity 214 in a bit 150 and securedthereto by a resilient or ductile connecting element 216 which extendsinto aperture 218 at the top of cavity 214. Connecting element 216 maycomprise, for example, an elastomeric block, a coil spring, a bellevillespring, a leaf spring, or a block of ductile metal, such as steel orbronze. Thus, connecting element 216, as with the ball and socketconnections 196 and heads 192, permits head 212 to automatically adjustto, or compensate for, varying ROPs defining different cutter helixangles. DOCC feature 220 employs a yoke 222 rotationally disposed andpartially received within cavity 224, yoke 222 supported on protrusion226 of bit 150. Stops 228, of resilient or ductile materials (such aselastomers, steel, lead, etc.) and which may be permanent orreplaceable, permit yoke 222 to accommodate various helix angles. Yoke222 may be secured within cavity 224 by any conventional means. Sincehelix angles vary even for a given, specific ROP as distance of eachcutter from the bit centerline, affording such automatic adjustment orcompensation may be preferable to trying to form DOCC features withbearing surfaces at different angles at different locations over the bitface.

FIGS. 10A and 10B respectively depict different DOCC features and PDCcutter combinations. In each instance, a PDC cutter 14 is secured to acombined cutter carrier and DOC limiter 240, the cutter carrier and DOClimiter 240 being received within a cavity 242 in the face (or on ablade) of an exemplary bit 150 and secured therein as by brazing,welding, mechanical fastening, or otherwise as known in the art. Thecutter carrier and DOC limiter 240 includes a protrusion 244 exhibitinga bearing surface 246. As shown and by way of example only, bearingsurface 246 may be substantially flat (FIG. 10A) or hemispherical (FIG.10B). By selecting an appropriate cutter carrier and DOC limiter 240,the DOC of PDC cutter 14 may be varied and the surface area of bearingsurface 246 adjusted to accommodate a target formation's compressivestrength.

It should be noted that the DOCC features of FIGS. 7 through 10, inaddition to accommodating different formation compressive strengths, aswell as optimizing DOC and permitting minimization of friction-causingbearing surface area while preventing formation failure under WOB, alsofacilitate field repair and replacement of DOCC features due to drillingdamage or to accommodate different formations to be drilled in adjacentformations, or intervals, to be penetrated by the same borehole.

FIG. 11 depicts a DOCC feature 250 comprised of an annular cavity orchannel 252 in the face of an exemplary bit 150. Radially adjacent PDCcutters 14 flanking annular channel 252 cut the formation 254 but do notcut annular segment 256, which protrudes into annular cavity 252. At thetop 260 of annular channel 252, a flat-edged PDC cutter 258 (orpreferably a plurality of rotationally spaced cutters 258) truncatesannular segment 256 in a controlled manner so that the height of annularsegment 256 remains substantially constant and limits the DOC offlanking PDC cutters 14. In this instance, the bearing surface of theDOCC feature 250 comprises the top 260 of annular channel 252, and thesides 262 of channel 252 prevent collapse of annular segment 256. Ofcourse, it is understood that multiple annular channels 252 withflanking PDC cutters 14 may be employed and that a source of drillingfluid, such as aperture 264, would be provided to lubricate channel 252and flush formation cuttings from PDC cutter 258.

FIGS. 12 and 12A depict a low-friction, hydraulically enhanced DOCCfeature 270 comprised of a DOCC pad 272 rotationally leading a PDCcutter 14 across fluid course 20 on exemplary bit 150, pad 272 beingprovided with drilling fluid through passage 274 leading to the bearingsurface 276 of pad 272 from a plenum 278 inside the body of bit 150. Asshown in FIG. 12A, a plurality of channels 282 may be formed on bearingsurface 276 to facilitate distribution of drilling fluid from the mouth280 of passage 274 across bearing surface 276. By diverting a smallportion of drilling fluid flow to the bit 150 from its normal pathleading to nozzles associated with the cutters, it is believed that theincreased friction normally attendant with WOB increases after thebearing surface 276 of DOCC pad 272 contacts the formation may be atleast somewhat alleviated or, in some instances, substantially avoided,which may reduce or eliminate torque increases responsive to increasesof WOB. Of course, passages 274 may be sized to provide appropriateflow, or pads 272 sized with appropriately dimensioned mouths 280. Pads272 may, of course, be configured for replaceability.

As has been mentioned above, backrakes of the PDC cutters employed in abit equipped with DOCC features according to the invention may be moreaggressive, that is to say, less negative, than with conventional bits.It is also contemplated that extremely aggressive cutter rakes,including neutral rakes and even positive (forward) rakes of thecutters, may be successfully employed consistent with the cutters'inherent strength to withstand the loading thereon as a consequence ofsuch rakes, since the DOCC features will prevent such aggressive cuttersfrom engaging the formation to too great a depth.

It is also contemplated that two different heights, or exposures, ofbearing segments may be employed on a bit, a set of higher bearingsegments providing a first bearing surface area supporting the bit onharder, higher compressive strength formations providing a relativelyshallow DOC for the PDC cutters of the bit, while a set of lower bearingsegments remains out of contact with the formation while drilling untila softer, lower compressive stress formation is encountered. At thatjuncture, the higher or more exposed bearing segments will be ofinsufficient surface area to prevent indentation (failure) of theformation rock under applied WOB. Thus, the higher bearing segments willindent the formation until the second set of bearing segments comes incontact therewith, whereupon the combined surface area of the two setsof bearing segments will support the bit on the softer formation, but ata greater DOC to permit the cutters to remove a greater volume offormation material per rotation of the bit and thus generate a higherROP for a given bit rotational speed. This approach differs from theapproach illustrated in FIG. 5, in that, unlike stepped DOCC features(feature 130), bearing segments of differing heights or exposures areassociated with different cutters. Thus, this aspect of the inventionmay be effected, for example, in the bits 10 and 100 of FIGS. 1 and 2 byfabricating selected arcuate bearing segments to a greater height orexposure than others. Thus, bearing segments 30 b and 30 e of bits 10and 100 may exhibit a greater exposure than segments 30 a, 30 c, 30 dand 30 f, or vice versa.

Cutters employed with bits 10 and 100, as well as other bits disclosedthat will be discussed subsequently herein, are depicted as having PDCcutters 14, but it will be recognized and appreciated by those ofordinary skill in the art that the invention may also be practiced onbits carrying other types of superabrasive cutters, such as thermallystable polycrystalline diamond compacts, or TSPs, for example, arrangedinto a mosaic pattern as known in the art to simulate the cutting faceof a PDC. Diamond film cutters may also be employed, as well as cubicboron nitride compacts.

Another embodiment of the present invention, as exemplified by rotarydrill bits 300 and 300′, is depicted in FIGS. 14A-20. Rotary drill bits,such as drill bits 300 and 300′, according to the present invention, mayinclude many features and elements which correspond to those identifiedwith respect to previously described and illustrated bits 10 and 100.

Representative rotary drill bit 300 shown in FIGS. 14A and 14B, includesa bit body 301 having a leading end 302 and a trailing end 304.Connection 306 may comprise a pin-end connection having tapered threadsfor connecting bit 300 to a bottom hole assembly of a conventionalrotating drill string, or alternatively, for connection to a downholemotor assembly, such as a drilling fluid powered Moineau-type downholemotor, as described earlier. Leading end 302, or drill bit face,includes a plurality of blade structures 308 generally extendingradially outwardly and longitudinally toward trailing end 304. Exemplarybit 300 comprises eight blade structures 308, or blades, spacedcircumferentially about the bit. However, a fewer number of blades maybe provided on a bit such as provided on bit body 301′ of bit 300′ shownin FIG. 14C which has six blades. A greater number of blade structuresof a variety of geometries may be utilized as determined to be optimumfor a particular drill bit. Furthermore, blade structures 308 need notbe equidistantly spaced about the circumference of drill bit 300 asshown, but may be spaced about the circumference, or periphery, of a bitin any suitable fashion, including a non-equidistant arrangement or anarrangement wherein some of the blades 308 are spaced circumferentiallyequidistantly from each other and some are irregularly,non-equidistantly spaced from each other. Moreover, blade structures 308need not be specifically configured in the manner as shown in FIGS. 14Aand 14B, but may be configured to include other profiles, sizes, andcombinations than those shown.

Generally, a bit, such as bit 300, includes a cone region 310, a noseregion 312, a flank region 314, a shoulder region 316, and a gage region322. Frequently, a specific distinction between flank region 314 andshoulder region 316 may not be made. Thus, the term “shoulder,” as usedin the art, will often incorporate the “flank” region within the“shoulder” region. Fluid ports 318 are disposed about the face of thebit 300 and are in fluid communication with at least one interiorpassage provided in the interior of bit body 301 in a manner such asillustrated in FIG. 2A of the drawings and for the purposes describedpreviously herein. Preferably, but not necessarily, fluid ports 318include nozzles 338 disposed therein to better control the expulsion ofdrilling fluid from bit body 301 into fluid courses 344 and junk slots340 in order to facilitate the cooling of cutters on bit 300 and theflushing of formation cuttings up the borehole toward the surface whenbit 300 is in operation.

Blade structures 308 preferably comprise, in addition to gage region322, a radially outward facing bearing surface 320, a rotationallyleading surface 324, and a rotationally trailing surface 326. That is,as the bit 300 is rotated in a subterranean formation to create aborehole, leading surface 324 will be facing the intended direction ofbit rotation while trailing surface 326 will be facing opposite, orbackwards from, the intended direction of bit rotation. A plurality ofcutting elements, or cutters 328, is preferably disposed along andpartially within blade structures 308. Specifically, cutters 328 arepositioned so as to have a superabrasive cutting face, or table 330,generally facing in the same direction as leading surface 324, as wellas to be exposed to a certain extent beyond bearing surface 320 of therespective blade in which each cutter is positioned. Cutters 328 arepreferably superabrasive cutting elements known within the art, such asthe exemplary PDC cutters described previously herein, and arephysically secured in pockets 342 by installation and securementtechniques known in the art. The preferred amount of exposure of cutters328 in accordance with the present invention will be described infurther detail hereinbelow.

Optional wear knots, wear clouds, or built-up wear-resistant areas,collectively referred to as wear knots 334 herein, may be disposed upon,or otherwise provided on bearing surfaces 320 of blade structures 308with wear knots 334 preferably being positioned so as to rotationallyfollow cutters 328 positioned on respective blades or other surfaces inwhich cutters 328 are disposed. Wear knots 334 may be originally moldedinto bit 300 or may be added to selected portions of bearing surface320. As described earlier herein, bearing surfaces 320 of bladestructures 308 may be provided with other wear-resistant features orcharacteristics, such as embedded diamonds, TSPs, PDCs, hard facing,weldings, and weldments for example. As will become apparent, suchwear-resistant features can be employed to further enhance and augmentthe DOCC aspect as well as other beneficial aspects of the presentinvention.

FIGS. 15A-15C highlight the extent in which cutters 328 are exposed withrespect to the surface immediately surrounding cutters 328 andparticularly cutters 328C located within the radially innermost regionof the leading end of a bit proximate the longitudinal centerline of thebit. FIG. 15A provides a schematic representation of a representativegroup of cutters provided on a bit as the bit rotatingly engages aformation with the cutter profile taken in cross-section and projectedonto a single, representative vertical plane (i.e., the drawing sheet).Cutters 328 are generally radially, or laterally, positioned along theface of the leading end of a bit, such as representative bit 300, so asto provide a selected center-to-center radial, or lateral spacingbetween cutters referred to as center-to-center cutter spacing R_(s).Thus, if a bit is provided with a blade structure, such as bladestructures 308, the cutter profile of 15A represents the cutterspositioned on a single representative blade structure 308. Asexaggeratedly illustrated in FIG. 15A, cutters 328C located in coneregion 310 are preferably disposed into blade structures 308 so as tohave a cutter exposure H_(c) generally perpendicular to the outwardlyface bearing surface 320 of blade structures 308 by a selected amount.As can be seen in FIG. 15A, cutter exposure H_(c) is of a preferablyrelative small amount of standoff, or exposure, distance in cone region310 of bit 300. Preferably, cutter exposure H_(c) generally differs foreach of the cutters or groups of cutters positioned more radiallydistant from centerline L. For example cutter exposure H_(c) isgenerally greater for cutters 328 in nose region 312 than it is forcutters 328 located in cone region 310 and cutter exposure H_(c) ispreferably at a maximum in flank/shoulder regions 314/316. Cutterexposure H_(c) preferably diminishes slightly radially toward gageregion 322, and radially outermost cutters 328 positioned longitudinallyproximate gage pad surface 354 of gage region 322 may incorporatecutting faces of smaller cross-sectional diameters as illustrated. Gageline 352 (see FIGS. 16 and 17) defines the maximum outside diameter ofbit 300.

The cross-sectional profile of optional wear knots 334, wear clouds,hard facing, or surface welds have been omitted for clarity in FIG. 15A.However, FIG. 15C depicts the rotational cross-sectional profile, assuperimposed upon a single, representative vertical plane ofrepresentative optional wear knots 334, wear clouds, hard facing,surface welds, or other wear knot structures. FIG. 15C furtherillustrates an exemplary cross-sectional wear knot height H_(wk)measured generally perpendicular to outwardly face bearing surface 320.There may or may not be a generally radial dimensional difference, orrelief, ΔH_(c-wk), between wear knot height H_(wk) , which generallycorresponds to a radially outermost surface of a given wear knot orstructure, and respective cutter exposure H_(c), which generallycorresponds to the radially outermost portion of the rotationallyassociated cutter, to further provide a DOCC feature in accordance withthe present invention. Conceptually, these differences in exposures canbe regarded as analogous to the distance of PDC cutter 14 androtationally trailing DOC limiter 50 as measured from the dashedreference line illustrated in FIG. 4 and as described earlier.Furthermore, instead of referring to the distance in which the radiallyoutermost surface of a given wear knot structure is positioned radiallyoutward from a bearing surface or blade structure in which a particularwear knot structure is disposed upon, it may be helpful to alternativelyrefer to a preselected distance in which the radially outermost surfaceof a given wear knot structure is radially/longitudinally inset, orrelieved, from the outermost portion of the exposed portion of arotationally associated superabrasive cutter as denoted as ΔH_(c-wk) inFIG. 15C. Thus, in addition to controlling the DOC with at least certaincutters, and perhaps every cutter, by selecting an appropriate cutterexposure height H_(c) as defined and illustrated herein, the presentinvention further encompasses optionally providing drill bits with wearknots, or other similar cutter depth limiting structures, to complement,or augment, the control of the DOCs of respectively rotationallyassociated cutters, wherein such optionally provided wear knots aredisposed on the bit so as to have a wear knot surface that ispositioned, or relieved, a preselected distance ΔH_(c-wk) as measuredfrom the outermost exposed portion of the cutter in which a wear knot isrotationally associated to the wear knot surface.

The superimposed cross-sectional cutter profile of a representativedrill bit such as bit 300 in FIG. 15B depicts the combined profile ofall cutters installed on each of a plurality of blade structures 308 soas to have a selected center-to-center radial cutter spacing R_(s).Thus, the cutter profile illustrated in FIG. 15B is the result of all ofthe cutters provided on a plurality of blades and rotated about thecenterline of the bit to be superimposed upon a single, representativeblade structures 308. In some embodiments, there will likely be severalcutter redundancies at identical radial locations between variouscutters positioned on respective, circumferentially spaced blades, and,for clarity, such profiles which are perfectly, or absolutely, redundantare typically not illustrated. As can be seen in FIG. 15B, there will bea lateral, or radial, overlap between respective cutter paths as thevariously provided cutters rotationally progress generally tangential tolongitudinal axis L as the bit 300 rotates so as to result in a uniformcutting action being achieved as the drill bit rotatingly engages aformation under a selected WOB. Additionally, it can be seen in FIG. 15Bthat the lateral, or radial, spacing between individual cutter profilesneed not be of the same, uniform distance with respect to the radial, orlateral, position of each cutter. This non-uniform spacing with respectto the radial, or lateral, positioning of each cutter is more clearlyillustrated in FIGS. 16 and 17.

FIGS. 16 and 17 are enlarged, isolated partial cross-sectional cutterprofile views to which all of the cutters located on a bit aresuperimposed as if on a single cross-sectional portion of a bit body 301or cutters 328 of a bit, such as bit 300. The cutter profiles of FIGS.16 and 17 are illustrated as being to the right of longitudinalcenterline L of a representative bit, such as bit 300, instead of theleft, as illustrated in FIGS. 15A-15C. As described, the leading end ofbit 300 includes cone region 310, which includes cutters 328C; noseregion 312, which includes cutters 328N; flank region 314, whichincludes cutters 328F; shoulder region 316, which includes cutters 328S;and gage region 322, which includes cutters 328G; wherein the cutters ineach region may be referred to collectively as cutters 328. FIG. 16illustrates a cutter profile exhibiting a high degree, or amount, ofcutter overlap 356. That is, cutters 328 as illustrated in FIG. 17 areprovided in sufficient quantity and are positioned sufficiently close toeach other laterally, or radially, so as to provide a high degree ofcutter redundancy as the bit rotates and engages the formation. Incontrast, the representative cutter profile illustrated in FIG. 17exhibits a relatively lower degree, or amount, of cutter overlap 356.That is, the total number of cutters 328 is less in quantity and arespaced further apart with respect to the radial, or lateral, distancebetween individual, rotationally adjacent cutter profiles. Kerf regions348, shown in phantom, in FIGS. 16 and 17 reveal a relatively smallheight for kerf regions 348 of FIG. 16 wherein kerf regions of FIG. 17are significantly higher. To aid in the illustration of the respectivedifferences in individual kerf region height K_(H), which, as apractical matter, is directly related to cutter exposure height H_(C),as well as individual kerf region widths K_(w), which are directlyinfluenced by the extent of radial overlap of cutters respectivelypositioned on different blades, a scaled reference grid of a pluralityof parallel spaced lines is provided in FIGS. 16 and 17 to highlight thecutter exposure height and kerf region widths. The spacing between thegrid lines in FIGS. 16 and 17 are scaled to represent approximately0.125 of an inch. However, such a 0.125, or ⅛ inch, scale grid is merelyexemplary, as dimensionally greater as well as dimensionally smallercutter exposure heights, kerf region heights K_(H), and kerf regionwidths K_(W) may be used in accordance with the present invention. Thesuperimposed cutter profile of cutters 328 is illustrated with each ofthe represented cutters 328 being generally equidistantly spaced alongthe face of the bit 300 from centerline L toward gage region 322,however, such need not be the case. For example, cutters 328C may have acutter profile exhibiting more cutter overlap 356 resulting in smallkerf widths K_(W) in cone region 310 as compared to a cutter profile ofcutters 328N, 328F, and 328S respectively located in nose region 312,flank region 314, and shoulder region 316, wherein such more radiallyoutward positioned cutters 328 would have less overlap resulting inlarger kerf widths K_(W) therein, or vice versa. Thus, by selectivelyincorporating the amount of cutter overlap 356 to be provided in eachregion of a bit, the depth of cut of the cutters in combination withselecting the degree or amount of cutter exposure height of each cutterlocated in each particular region may be utilized to specifically andprecisely control the depth of cut in each region, as well as to designinto the bit the amount of available bearing surface surrounding thecutters to which the bit may ride upon the formation. Stateddifferently, the wider the kerf width K_(w) between the collective,superimposed, individual cutter profiles of all the cutters on all ofthe blades, or alternatively, all the cutters radially andcircumferentially spaced about a bit, such as cutters 328 provided on abit as shown in FIG. 17, a greater proportion of the total applied WOBwill be dispersed upon the formation allowing the bit to “ride” on theformation than would be the case if a greater quantity of cutters wereprovided having a smaller kerf width K_(w) therebetween, as shown inFIG. 16.

Therefore, the cutter profile illustrated in FIG. 17 would result in aconsiderable portion of the WOB being applied to bit 300 to be dispersedover the wide kerfs and thereby allowing bit 300 to be supported by theformation as cutters 328 engage the formation. This feature of selectingboth the total number of kerfs and the widths of the individual kerfwidths K_(w) allows for a precise control of the individualdepth-of-cuts of the cutters adjacent the kerfs, as well as the totalcollective depth-of-cut of bit 300 into a formation of a given hardness.Upon a great enough, or amount of, WOB being applied on the bit whendrilling in a given relatively hard formation, the kerf regions 348would come to ride upon the formation, thereby limiting, or arresting,the DOC of cutters 328. If yet further WOB were to be applied, the DOCwould not increase as the kerf regions 348, as well as portions of theoutwardly facing surface of the blade surrounding each cutter 328provided with a reduced amount of exposure in accordance with thepresent invention, would, in combination, provide a total amount ofbearing surface to support the bit in the relative hard formation,notwithstanding an excessive amount of WOB being applied to the bit inlight of the current ROP.

Contrastingly, in a bit provided with a cutter profile exhibitingdimensionally small cutter-to-cutter spacings by incorporating arelatively high quantity of cutters 328 with a small kerf region K_(w)between mutually radially, or laterally, overlapped cutters, such asillustrated in FIG. 16, each individual cutter would engage theformation with a lesser amount of DOC per cutter at a given WOB. Becauseeach cutter would engage the formation at a lesser DOC as compared withthe cutter profile of FIG. 17, with all other variables being heldconstant, the cutters of the cutter profile of FIG. 16 would tend to bebetter suited for engaging a relatively hard formation where a large DOCis not needed, and is, in fact, not preferred for engaging and cutting ahard formation efficiently. Upon a requisite, or excessive amount of WOBfurther being applied on a bit having the cutter profile of FIG. 16 inlight of the current ROP being afforded by the bit, kerf regions 348would come to ride upon the formation, as well as other portions of theoutwardly facing blade surface surround each cutter 328 exhibiting areduced amount of exposure in accordance with the present invention tolimit the DOC of each cutter by providing a total amount of bearingsurface to disperse the WOB onto the formation being drilled. Ingeneral, larger kerfs will promote dynamic stability over formationcutting efficiency, while smaller kerfs will promote formation cuttingefficiency over dynamic stability.

Furthermore, the amount of cutter exposure that each cutter is designedto have will influence how quickly, or easily, the bearing surfaces willcome into contact and ride upon the formation to axially disperse theWOB being applied to the bit. That is, a relatively small amount ofcutter exposure will allow the surrounding bearing surface to come intocontact with the formation at a lower WOB while a relatively greateramount of cutter exposure will delay the contact of the surroundingbearing surface with the formation until a higher WOB is applied to thebit. Thus, individual cutter exposures, as well as the mean kerf widthsand kerf heights may be manipulated to control the DOC of not only eachcutter, but the collective DOC per revolution of the entire bit as itrotatingly engages a formation of a given hardness and confiningpressure at given WOB.

Therefore, FIG. 16 illustrates an exemplary cutter profile particularlysuitable for, but not limited to, a “hard formation,” while FIG. 17illustrates an exemplary cutter profile particularly suitable for, butnot limited to, a “soft formation.” Although the quantity of cuttersprovided on a bit will significantly influence the amount of kerfprovided between radially adjacent cutters, it should be kept in mindthat both the size, or diameter, of the cutting surfaces of the cuttersmay also be selected to alter the cutter profile to be more suitable foreither a harder or softer formation. For example, cutters having largerdiameter superabrasive tables may be utilized to provide a cutterprofile, including dimensionally larger kerf heights and dimensionallylarger kerf widths to enhance soft formation cutting characteristics.Conversely, a bit may be provided with cutters having smaller diametersuperabrasive tables to provide a cutter profile exhibitingdimensionally smaller kerf heights and dimensionally smaller kerf widthsto enhance hard formation cutting characteristics of a bit in accordancewith the teachings herein.

Additionally, the full-gage diameter that a bit is to have will alsoinfluence the overall cutter profile of the bit with respect to kerfheights and kerf widths, as there will be a greater total amount ofbearing surface potentially available to support larger diameter bits ona formation, unless the bit is provided with a proportionately greaternumber of reduced exposure cutters and, if desired, conventionalcutters, so as to effectively reduce the total amount of potentialbearing surface area of the bit.

FIG. 18A of the drawings is an isolated, schematic, frontal view ofthree representative cutters 328C positioned in cone region 310 of arepresentative blade structures 308. Each of the representative cutters328C exhibits a preselected amount of cutter exposure so as to limit theDOC of the cutters 328C while also providing individual kerf regions 348between cutters 328C (in this particular illustration, kerf width K_(w)represents the kerf width between cutters which are located on the sameblade and exhibit a selected radial spacing R_(s)) and to which thebearing surface of the blade to which the cutters 328C are secured(surface 320C) provides a bearing surface, including kerf regions 348for the bit to ride, or rub, upon the formation, not currently being cutby this particular blade structures 308, upon the design WOB beingexceeded for a given ROP in a formation 350 of certain hardness, orcompressive strength. As can be seen in FIG. 18A, this particular viewshows a rotationally leading surface 324 advancing toward the viewer andshows superabrasive cutting face or tables 330 of cutters 328C engagingand creating a formation cutting 350′, or chip, as the cutters 328Cengage the formation at a given DOC.

FIG. 18B provides an isolated, side view of a representative reducedexposure cutter, such as cutter 328C located in cone region 310. Cutter328C is shown as being secured in a blade structure 308 at a preselectedbackrake angle θ_(br) and exhibits a selected exposed cutter heightH_(c). As can be seen in FIG. 18B, cutter 328C is provided with anoptional, peripherally extending chamfered region 321 exhibiting apreselected chamfer width C_(w). The arrow represents the intendeddirection of bit rotation when the bit in which the cutter 328C isinstalled is placed in operation. A gap referenced as G₁ can be seenrotationally rearwardly of cutter 328C. Cutter exposure height H_(c)allows a sufficient amount of cutter 328C to be exposed to allow cutter328C to engage formation 350 at a particular DOC1, which is well withinthe maximum DOC that cutter 328C is capable of engaging formation 350,to create a formation cutting 350′ at this particular DOC1. Thus, inaccordance with the present invention, the WOB now being applied to thebit in which cutter 328C is installed, is at a value less than thedesign WOB for the instant ROP and the compressive strength of formation350.

In contrast to FIG. 18B, FIG. 18C provides essentially the same sideview of cutter 328C upon the design WOB for the bit being exceeded forthe instant ROP and the compressive strength of formation 350. As can beseen in FIG. 18C, reduced exposure cutter 328C is now engaging formation350 at a DOC2, which happens to be the maximum DOC that this particularcutter 328C should be allowed to cut. This is because formation 350 isnow riding upon outwardly facing bearing surface 320C, which generallysurrounds the exposed portion of cutter 328C. That is, gap G₂ isessentially nil in that surface 320C and formation 350 are contactingeach other and surface 320C is sliding upon formation 350 as the bit towhich representative reduced exposure cutter 328C is rotated in thedirection of the reference arrow. Thus, especially in the absence ofoptional wear knots 334 (FIG. 14A), DOC2 is essentially limited to theamount of cutter exposure height H_(c) at the presently applied WOB inlight of the compressive strength of the formation being engaged at theinstant ROP. Even if the amount of WOB applied to the bit to whichcutter 328C is installed is increased further, DOC2 will not increase asbearing surface 320C, in addition to other bearing surfaces 320C on thebit accommodating reduced exposure of cutter 328C will prevent DOC2 fromincreasing beyond the maximum amount shown. Thus, bearing surface(s)320C surrounding at least the exposed portion of cutter 328C, takencollectively with other bearing surfaces 320C, will prevent DOC2 fromincreasing dimensionally to an extent which could cause an unwanted,potentially bit damaging TOB being generated due to cutter 328Coverengaging formation 350. That is, a maximum-sized formation cutting350″ associated with a reduced exposure cutter engaging the formation ata respective maximum DOC2, taken in combination with other reducedexposure cutters engaging the formation at a respective maximum DOC2,will not generate as taken in combination, a total, excessive amount ofTOB which would stall the bit when the design WOB for the bit is met orexceeded for the particular compressive strength of the formation beingengaged at the current ROP. Thus, the DOCC aspects of this particularembodiment are achieved by preferably ensuring that there is sufficientarea surrounding each reduced exposure cutter 328C, such asrepresentative reduced exposure cutter 328C, so that not only is theDOC2 for this particular cutter 328C, not exceeded, regardless of theWOB being applied, but preferably the DOC of a sufficient number ofother cutters provided along the face of a bit encompassing the presentinvention is limited to an extent which prevents an unwanted,potentially damaging TOB from being generated. Therefore, it is notnecessary that each and every cutter provided on a drill bit exhibit areduced exposure cutter height so as to effectively limit the DOC ofeach and every cutter, but it is preferred that at least a sufficientquantity of cutters of the total quantity of cutters provided on a bitbe provided with at least one of the DOCC features disclosed herein topreclude a bit, and the cutters thereon, from being exposed to apotentially damaging TOB in light of the ROP for the particularformation being drilled. For example, limiting the amount of cutterexposure of each cutter positioned in the cone region of a drill bit maybe sufficient to prevent an unwanted amount of TOB should the WOB exceedthe design WOB when drilling through a formation of a particularhardness at a particular ROP.

FIGS. 19-22 are graphical portrayals of laboratory test results of fourdifferent bladed-style drill bits incorporating PDC cutters on theblades thereof. Drill bits labeled “RE-S” and “RE-W” each hadselectively reduced cutter exposures in accordance with the presentinvention as previously described and illustrated in FIGS. 14A-18C.However, drill bit labeled “RE-S” was provided with a cutter profileexhibiting small kerfs and drill bit labeled “RE-W” was provided with acutter profile exhibiting wide kerfs. The bits having reduced exposurecutters are graphically contrasted with the laboratory test results of aprior art steerable bit labeled “STR” including approximately 0.50-inchdiameter cutters with each cutter including a superabrasive table havinga peripheral edge chamfer exhibiting a width of approximately 0.050 inchand angled toward the longitudinal axis of the cutter by approximately45°. Conventional, or standard, general purpose drill bit labeled “STD”included approximately 0.50-inch diameter cutters backraked atapproximately 20° and exhibiting chamfers of approximately 0.016 inch inwidth and angled approximately 45° with respect to the longitudinal axisof the cutter. All bits had a gage diameter of approximately 12.25inches and were rotated at 120 rpm during testing. With respect to allof the tested bits, the PDC cutters installed in the cone, nose, flank,and shoulder of the bits had cutter backrake angles of approximately 20°and the PDC cutters installed generally within the gage region had acutter backrake angle of approximately 30°. The cutter exposure heightsof the RE-S and RE-W bits were approximately 0.120 inch for the cutterspositioned in the cone region, approximately 0.150 inch in the noseregion, approximately 0.100 inch in the flank region, approximately0.063 inch in the shoulder region, and the cutters in the gage regionwere generally ground flush with the gage for both of these bitsembodying the present invention. The PDC cutters of the RE-S and RE-Wbits were approximately 0.75 inch in diameter (with the exception of PDCcutters located in the gage region, which were smaller in diameter andground flush with the gage) and were provided with a chamfer on theperipheral edge of the superabrasive cutting table of the cutter. Thechamfers exhibited a width of approximately 0.019 inch and were angledtoward the longitudinal axes of the cutters by approximately 45°. Themean kerf width of the RE-S bit was approximately 0.3 inch and the meankerf width of the RE-W bit was approximately 0.2 inch.

FIG. 19 depicts test results of Aggressiveness (μ) vs. DOC (in/rev) ofthe four different drill bits. Aggressiveness (μ), which is defined asTorque/(Bit Diameter×Thrust), can be expressed as:μ=36Torque (ft-lbs)/WOB(lbs)·Bit Diameter(inches)The values of DOC depicted in FIG. 19 represent the DOC measured ininches of penetration per revolution that the test bits made in the testformation of Carthage limestone. The confining pressure of the formationin which the bits were tested was at atmospheric, or 0 psig.

Of significance is the encircled region labeled “D” as shown in thegraph of FIG. 19. The plot of bit RE-S prior to encircled region D isvery similar in slope to prior art steerable bit STR but upon the DOCreaching about 0.120 inch, the respective aggressiveness of the RE-S bitfalls rather dramatically compared to the plot of the STR bit proximateand within encircled region D. This is attributable to the bearingsurfaces of the RE-S bit taking on and axially dispersing the elevatedWOB upon the formation axially underlying the bit associated with thelarger DOCs, such as the DOCs exceeding approximately 0.120 inch inaccordance with the present invention.

FIG. 20 graphically portrays the test results with respect to WOB inpounds versus ROP in feet per hour with a drill bit rotation of 120revolutions per minute. Of general importance in the graph of FIG. 20 isthat all of the plots tend to have the same flat curve as WOB and ROPinitially increases. Thus, at lower WOBs and lower ROPs, of the RE-S andRE-W bits embodying the present invention exhibit generally the samebehavior as the STR and STD bits. However, as WOB was increased, theRE-S bit in particular required an extremely high amount of WOB in orderto increase the ROP for the bit due to the bearing surfaces of the bittaking on and dispersing the axial loading of the bit. This is evidencedby the plot of the reduced cutter exposure bit in the vicinity of regionlabeled “E” of the graph exhibiting a dramatic upward slope. Thus, inorder to increase the ROP of the subject inventive bit at ROP valuesexceeding about 75 ft/hr, a very significant increase of WOB wasrequired for WOB values above approximately 20,000 lbs as the load onthe subject bit was successfully dispersed on the formation axiallyunderlying the bit. The fact that a WOB of approximately 40,000 lbs wasapplied without the RE-S bit stalling provides very strong evidence ofthe effectiveness of incorporating reduced exposure cutters to modulateand control TOB in accordance with the present invention as will becomeeven more apparent in yet to be discussed FIG. 22.

FIG. 21 is a graphical portrayal of the test results in terms of TOB inthe units of pounds-foot versus ROP in the units of feet per hour. Ascan be seen in the graph of FIG. 21, the various plots of the testedbits generally tracked the same, moderate and linear slope throughoutthe respective extent of each plot. Even in the region labeled “F” ofthe graph, where ROP was over 80 ft/hr, the TOB curve of the bit havingreduced exposure cutters exhibited only slightly more TOB as compared tothe prior art steerable and standard, general purpose bitnotwithstanding the corresponding highly elevated WOB being applied tothe subject inventive bit as shown in FIG. 20.

FIG. 22 is a graphical portrayal of the test results in terms of TOB inthe units of foot-pounds versus WOB in the units of pounds. Ofparticular significance with respect to the graphical data presented inFIG. 22 is that the STD bit provides a high degree of aggressivity atthe expense of generating a relatively high amount of TOB at lower WOBs.Thus, if a generally non-steerable, standard bit were to suddenly “breakthrough” a relative hard formation into a relatively soft formation, orif WOB were suddenly increased for some reason, the attendant high TOBgenerated by the highly aggressive nature of such a conventional bitwould potentially stall and/or damage the bit.

The representative prior art steerable bit generally has an efficientTOB/WOB slope at WOBs below approximately 20,000 lbs, but at WOBsexceeding approximately 20,000 lbs, the attendant TOB is unacceptablyhigh and could lead to unwanted bit stalling and/or damage. The RE-W bitincorporating the reduced exposure cutters in accordance with thepresent invention, which also incorporated a cutter profile having largekerf widths so that the onset of the bearing surfaces of the bitcontacting the formation occurs at relatively low values of WOB.However, the bit having such an “always rubbing the formation”characteristic via the bearing surfaces, such as formation facingbearing surfaces 320 of blade structures 308 as previously discussed andillustrated herein, coming into contact and axially dispersing theapplied WOB upon the formation at relatively low WOBs, may provideacceptable ROPs in soft formations, but such a bit would lack the amountof aggressivity needed to provide suitable ROPs in harder, firmerformations and thus could be generally considered to exhibit aninefficient TOB versus WOB curve.

The representative RE-S bit incorporating reduced exposure cutters ofthe present invention and exhibiting relatively small kerf widthseffectively delayed the bearing surfaces (for example, including, butnot limited to, bearing surface 320 of blade structures 308 aspreviously discussed and illustrated herein) surrounding the cuttersfrom contacting the formation until relatively higher WOBs were appliedto the bit. This particularly desirable characteristic is evidenced bythe plot for the RE-S bit at WOB values greater than approximately20,000 lbs and exhibits a relatively flat and linear slope as the WOB isapproximately doubled to 40,000 lbs with the resulting TOB onlyincreasing by about 25% from a value of about 3,250 ft-lbs to a value ofapproximately 4,500 ft-lbs. Thus, considering the entire plot for thesubject inventive bit over the depicted range of WOB, the RE-S bit isaggressive enough to efficiently penetrate firmer formations at arelatively high ROP, but if WOB should be increased, such as by loss ofcontrol of the applied WOB, or upon breaking through from a hardformation into a softer formation, the bearing surfaces of the bitcontact the formation in accordance with the present invention to limitthe DOC of the bit as well as to modulate the resulting TOB so as toprevent stalling of the bit. Because stalling of the bit is prevented,the unwanted occurrence of losing tool face control or worse, damage tothe bit, is minimized if not entirely prevented in many situations.

It can now be appreciated that the present invention is particularlysuitable for applications involving extended reach or horizontaldrilling where control of WOB becomes very problematic due tofriction-induced drag on the bit, downhole motor if being utilized, andat least a portion of the drill string, particularly that portion of thedrill string within the extended reach, or horizontal, section of theborehole being drilled. In the case of conventional, general purposefixed cutter bits, or even when using prior art bits designed to haveenhanced steerability, which exhibit high efficiency, that is, theability to provide a high ROP at a relatively low WOB, the bit will beespecially prone to large magnitudes of WOB fluctuation, which can varyfrom 10 to 20 klbs (10,000 to 20,000 pounds) or more, as the bit lurchesforward after overcoming a particularly troublesome amount of frictionaldrag. The accompanying spikes in TOB resulting from the sudden increasein WOB may in many cases be enough to stall a downhole motor or damage ahigh efficient drill bit and or attached drill string when using aconventional drill string driven by a less sophisticated conventionaldrilling rig. If a bit exhibiting a low efficiency is used, that is, abit that requires a relatively high WOB is applied to render a suitableROP, the bit may not be able to provide a fast enough ROP when drillingharder, firmer formations. Therefore, when practicing the presentinvention of providing a bit having a limited amount of cutter exposureabove the surrounding bearing surface of the bit and selecting a cutterprofile which will provide a suitable kerf width and kerf height, a bitembodying the present invention will optimally have a high enoughefficiency to drill hard formations at low depths-of-cut, but exhibit atorque ceiling that will not be exceeded in soft formations when WOBsurges.

While the present invention has been described herein with respect tocertain preferred embodiments, those of ordinary skill in the art willrecognize and appreciate that it is not so limited and many additions,deletions, and modifications to the preferred embodiments may be madewithout departing from the scope of the invention as claimed. Inaddition, features from one embodiment may be combined with features ofanother embodiment while still being encompassed within the scope of theinvention. Further, the invention has utility in both full bore bits andcore bits, and with different and various bit profiles as well as cuttertypes, configurations and mounting approaches.

1. A method of drilling a subterranean formation without generating anexcessive amount of torque-on-bit, comprising: engaging a formationhaving a compressive strength with at least one cutter of a drillingapparatus within a selected depth-of-cut range; applying a weight-on-bitwithin a range of weight-on-bit in excess of that required for the atleast one cutter to penetrate the formation and which results in atleast one bearing surface on a portion of the drilling apparatusimmediately proximate the at least one cutter contacting the formationto cause an area of the at least one bearing surface contacting theformation to remain substantially constant; and transferring the excessweight-on-bit through the at least one bearing surface to the formationat a stress less than substantially the compressive strength of theformation.
 2. The method of claim 1, wherein transferring the excessweight-on-bit through at least one bearing surface to the formationcomprises transferring the excess weight-on-bit through at least onebearing surface to the formation without precipitating substantialplastic deformation thereof.
 3. The method of claim 1, whereintransferring the excess weight-on-bit to at least one formation-facingbearing surface on the drilling apparatus immediately proximate the atleast one cutter comprises transferring the excess weight-on-bit to ahard facing material affixed to a selected portion of the at least oneformation-facing bearing surface proximate at least one cutter.
 4. Themethod of claim 1, further comprising: applying an additionalweight-on-bit in excess of the excess weight-on-bit required for the atleast one bearing surface to contact the formation; and transferring theadditional excess weight-on-bit through the at least one bearing surfaceto the formation at a stress less than substantially the compressivestrength of the formation.
 5. A method of drilling a subterraneanformation without generating an excessive amount of torque-on-bit,comprising: applying weight-on-bit to a drilling apparatus substantiallyalong a longitudinal axis thereof; engaging the formation with aplurality of cutters located over a face of the drilling apparatuswithin a selected depth-of-cut range responsive to the appliedweight-on-bit; and limiting a magnitude of torque-on-bit responsive tolimiting a maximum depth-of-cut of cutters of the plurality of cutterslocated within a cone region of the face during application of aweight-on-bit substantially along the longitudinal axis in excess ofthat required for the cutters within the cone region to penetrate theformation within the selected depth-of-cut range.
 6. The method of claim5, further comprising limiting the maximum depth-of-cut of the cutterswithin the cone region during application of the excess weight-on-bitsubstantially along the longitudinal axis by providing at least oneformation-facing bearing surface on the drilling apparatus generallysurrounding at least a portion of at least some cutters within the coneregion and limiting an extent of exposure of the at least some cuttersgenerally perpendicular to the at least one formation-facing bearingsurface.
 7. The method of claim 6, further comprising maintaining themaximum depth-of-cut of the cutters within the cone region under theapplied excess weight-on-bit substantially along the longitudinal axisby providing a total formation-facing bearing area on the drillingapparatus sufficient to axially support the drilling apparatus on theformation under the applied excess weight-on-bit substantially along thelongitudinal axis without substantial failure of the formation axiallyunderlying the drilling apparatus.
 8. The method of claim 5, furthercomprising maintaining the selected depth-of-cut range under the appliedexcess weight-on-bit substantially along the longitudinal axis bysupporting the drilling apparatus on the formation without precipitatingsubstantial plastic deformation thereof.
 9. The method of claim 6,further comprising: applying a selected weight-on-bit substantiallyalong the longitudinal axis to cause the cutters within the cone regionof the drilling apparatus to engage the formation to a selected depth ofcut; and precluding subsequent penetration of the cutters within thecone region into the formation in excess of the selected depth of cutduring application of a weight-on-bit greater than the selected weightsubstantially along the longitudinal axis.
 10. The method of claim 9,further comprising maintaining the selected depth of cut under theapplied greater weight-on-bit substantially along the longitudinal axisby providing a bearing area on the drilling apparatus to distribute theapplied greater weight-on-bit substantially along the longitudinal axissufficient to achieve a unit load by the bearing area on the formationless than a compressive strength of the formation.
 11. The method ofclaim 6, further comprising respectively securing the at least somecutters within the cone region to a plurality of blade structuresextending radially outwardly from a longitudinal axis of the drillingapparatus generally toward a gage region of the drilling apparatus. 12.The method of claim 11, wherein limiting the maximum depth-of-cut of thecutters within the cone region comprises respectively limiting theextent of exposure of the at least some cutters within the cone regionperpendicular to the respective at least one formation-facing bearingsurface proximate each of the at least some cutters within the coneregion to a selected cutter exposure height.
 13. The method of claim 12,wherein respectively limiting the extent of exposure of each of the atleast some cutters within the cone region perpendicular to therespective at least one formation-facing bearing surface proximate eachof the at least some cutters within the cone region to the selectedcutter exposure height comprises applying a hard facing material tobuild up a selected portion of the respective at least oneformation-facing bearing surface proximate the at least some cutterswithin the cone region so as to further limit the extent of exposure ofthe at least some cutters within the cone region.
 14. The method ofclaim 5, wherein limiting the maximum depth-of-cut of the cutters withinthe cone region comprises limiting the maximum depth-of-cut to generallyan equal amount of cutter exposure perpendicular to a selected portionof an outward face of a portion of the drilling apparatus to which eachof the cutters within the cone region is secured.
 15. The method ofclaim 5, wherein limiting the maximum depth-of-cut of the cutters withinthe cone region comprises limiting the maximum depth-of-cut to generallydiffering amounts of cutter exposure perpendicular to a selected portionof an outward face of a portion of the drilling apparatus to which eachof the cutters within the cone region is secured.
 16. The method ofclaim 5, further comprising: applying a first selected weight-on-bitsubstantially along the longitudinal axis to cause the cutters withinthe cone region to engage a first formation to a first selecteddepth-of-cut; precluding subsequent penetration of the cutters withinthe cone region into the first formation in excess of the maximumdepth-of-cut during application of an excessive weight-on-bitsubstantially along the longitudinal axis exceeding the first selectedweight-on-bit; applying a second selected weight-on-bit substantiallyalong the longitudinal axis different from the first selectedweight-on-bit to cause the cutters within the cone region to engage asecond formation to a second selected depth-of-cut different from thefirst selected depth-of-cut; and precluding subsequent penetration ofthe cutters within the cone region into the second formation in excessof the maximum depth-of-cut during application of an excessiveweight-on-bit substantially along the longitudinal axis exceeding thesecond selected weight-on-bit.
 17. A method of designing an apparatusfor drilling subterranean formations, the apparatus under designincluding a plurality of superabrasive cutters disposed about aformation-engaging portion of the apparatus, the method comprising:selecting a maximum depth-of-cut for at least some of the plurality ofsuperabrasive cutters; selecting a cutter profile arrangement for theformation-engaging portion of the apparatus to which the at least someof the plurality of superabrasive cutters are to be radially andlongitudinally positioned on the formation-engaging portion of theapparatus within a region of the cutter profile; selecting an individualextent of cutter exposure to which the at least some of the plurality ofsuperabrasive cutters within the region are to be exposed generallyperpendicular from at least one respective formation-facing bearingsurface at least partially surrounding the at least some of theplurality of superabrasive cutters within the region so as to ensurethat the selected maximum depth-of-cut for the at least some of theplurality of superabrasive cutters within the region is not exceeded;and including within the design of the apparatus substantially only asufficient total amount of formation-facing bearing surface area toaxially support the apparatus on a subterranean formation withoutexceeding the selected maximum depth-of-cut for the at least some of theplurality of superabrasive cutters within the region should theapparatus be subjected to a weight-on-bit substantially along alongitudinal axis of the apparatus exceeding a weight-on-bitsubstantially along the longitudinal axis which would cause the at leastsome of the plurality of superabrasive cutters within the region toengage the subterranean formation at the selected maximum depth-of-cut.18. The method of claim 17, further comprising determining for at leastone type of subterranean formation a first amount of weight-on-bit thatwill generate an associated amount of torque-on-bit responsive to whichthe at least some of the plurality of superabrasive cutters to beradially and longitudinally positioned on the formation-engaging portionof the apparatus will axially support the apparatus without the at leastone respective formation-facing bearing surface substantially contactingthe subterranean formation.
 19. The method of claim 17, furthercomprising including within the apparatus under design a plurality ofkerf regions of a preselected width positioned laterally intermediate ofselected rotationally adjacently positioned superabrasive cutters. 20.The method of claim 17, wherein selecting the individual extent ofcutter exposure to which the at least some of the plurality ofsuperabrasive cutters within the region are to be exposed comprisesselecting an individual extent of cutter exposure to which the at leastsome of the plurality of superabrasive cutters within the region are tobe exposed that is at least partially dependent upon a location of theregion of the cutter profile within which each of the at least some ofthe plurality of superabrasive cutters is to be positioned.
 21. Themethod of claim 20, wherein selecting the individual extent to which theat least some of the plurality of superabrasive cutters within theregion are to be exposed comprises selecting at least one individualextent of cutter exposure for at least one superabrasive cutter of theplurality to be located a cone region of the cutter profile.
 22. Themethod of claim 21, further comprising selecting a quantity of wearknots to be respectively positioned on the apparatus so at torotationally follow at least some of the plurality of superabrasivecutters.
 23. The method of claim 17, wherein selecting the individualextent to which the at least some of the plurality of superabrasivecutters within the region are to be exposed comprises selecting anamount of hard facing to be disposed on at least a portion of the atleast one respective formation-facing bearing surface at least partiallysurrounding the at least some of the plurality of superabrasive cutterswithin the region.
 24. The method of claim 17, wherein selecting theindividual extent of cutter exposure to which the at least some of theplurality of superabrasive cutters within the region are to be exposedcomprises generally selecting an individual extent of cutter exposurefor each of the plurality of superabrasive cutters within the region tobe the same amount.
 25. The method of claim 17, wherein selecting theindividual extent of cutter exposure to which the at least some of theplurality of superabrasive cutters within the region are to be exposedcomprises generally selecting an individual extent of cutter exposurefor each of the plurality of superabrasive cutters within the region tobe a mutually different amount.
 26. An apparatus for subterraneandrilling, comprising: a body including a portion for contacting aformation during drilling, and a trailing end having a structureassociated therewith for connecting the body to a drill string, theportion comprising a plurality of blade structures protruding from thebody, at least some blade structures of the plurality including at leastone of a plurality of bearing surfaces sized and configured, incombination, to transfer a range of weight-on-bit from the body throughthe plurality of bearing surfaces to the contacted formation, theplurality of bearing surfaces exhibiting in total a combined bearingsurface area of sufficient size to substantially maintain a stress onthe formation not exceeding a compressive strength thereof throughoutthe range of weight-on-bit; wherein a total area of contact with theformation of the plurality of bearing surfaces is configured and locatedto be substantially constant within the range of weight-on-bit; and aplurality of superabrasive cutters for engaging the formation duringdrilling, at least one superabrasive cutter of the plurality secured toeach blade structure of the plurality proximate a rotationally leadingsurface thereof facing a fluid course leading generally radially to ajunk slot, wherein at least one superabrasive cutter secured to at leastsome of the plurality of blade structures including at least one bearingsurface exhibits an exposure limited by the contact with the formationof an immediately proximate bearing surface area.
 27. The apparatusclaim 26, wherein the at least some of the plurality of blade structureseach extend from a respective point generally proximate a longitudinalcenterline of the body generally radially outward toward a gage of thebody and include a portion extending longitudinally toward the trailingend of the body.
 28. The apparatus of claim 26, wherein a maximumweight-on-bit of the range of weight-on-bit equals the combined bearingsurface area multiplied by the compressive strength of the formation.29. The apparatus of claim 26, wherein the at least some of theplurality of blade structures each carry several of the plurality ofsuperabrasive cutters and at least one bearing surface proximatethereto, and wherein each of the plurality of blade structures generallyencompasses each of the several of the plurality of superabrasivecutters carried thereon with a limited portion of each of the severalsuperabrasive cutters exposed by a preselected extent perpendicular fromthe respective at least one bearing surface proximate the severalsuperabrasive cutters so as to control a respective depth-of-cut foreach of the several superabrasive cutters.
 30. The apparatus of claim29, wherein at least a portion of the at least one bearing surface of atleast one of the plurality of blade structures includes a wear-resistantexterior.
 31. The apparatus of claim 29, wherein the portion of the bodycomprises a cone region and at least one other region of nose, flank,shoulder, and gage regions.
 32. The apparatus of claim 31 whereinsuperabrasive cutters of the plurality are located in at least two ofthe cone, nose, flank, shoulder and gage regions, and an exposure ofsuperabrasive cutters located in one region of the portion of the bodyis less than an exposure of cutters located in at least one other regionof the portion.
 33. An apparatus for subterranean drilling, comprising:a body having a longitudinal centerline including a portion forcontacting a formation having a maximum compressive strength duringdrilling and a trailing end having a structure associated therewith forconnecting the body to a drill string, the portion comprising aplurality of structures protruding from the body, at least somestructures of the plurality including at least one of a plurality ofsurfaces, the plurality of surfaces exhibiting a combined surface areaof sufficient size and orientation to substantially support the bodyresponsive to the body being longitudinally forced against the formationat a maximum weight-on-bit resulting in a unit load on the formation notexceeding the maximum compressive strength of the formation; a pluralityof superabrasive cutters for engaging the formation during drilling, atleast one superabrasive cutter of the plurality secured to eachstructure of the plurality proximate a rotationally leading surfacethereof facing a fluid course leading generally radially to a junk slot,at least some of the superabrasive cutters of the plurality beingpartially received in a structure surface and exhibiting a limitedamount of exposure perpendicular to the structure surface to, incombination with the combined surface area, limit a maximum depth-of-cutof the at least some superabrasive cutters.
 34. The apparatus of claim31, wherein the one or more bearing surfaces reside on at least in oneregion of the portion.
 35. The apparatus of claim 34, wherein theplurality of bearing surfaces reside substantially in the cone region ofthe portion.
 36. The apparatus of claim 35, wherein the several of theplurality of superabrasive cutters having at least one bearing surfaceimmediately proximate thereto exhibit a negative backrake.
 37. Theapparatus of claim 29, wherein the plurality of bearing surfacescomprise at least one wear knot structure proximate at least onesuperabrasive cutter of the plurality, the at least one wear knotstructure exhibiting a radially outermost wear knot surface that isgenerally inset a preselected distance from a rotational profileexhibited by an outermost portion of an exposed portion of at least onerotationally associated superabrasive cutter upon the body beingrotated.
 38. The apparatus of claim 37, wherein the at least one wearknot structure comprises a plurality of wear knot structures, at leastsome wear knot structures of the plurality proximate a rotationallyassociated superabrasive cutter.
 39. The apparatus of claim 26, whereinat least one superabrasive cutter of the plurality comprises a chamferedregion extending at least partially about a circumferential peripherythereof.
 40. The apparatus of claim 26, wherein the immediatelyproximate bearing surface area substantially surrounds the at least onesuperabrasive cutter on sides thereof and to the rear thereof, takenwith respect to a direction of intended bit rotation.
 41. The apparatusof claim 32, wherein the portion of the body comprises at least a coneregion and a nose region, and superabrasive cutters of the pluralitylocated in the cone region exhibit an exposure less than an exposure ofsuperabrasive cutters of the plurality in at least the nose region. 42.The apparatus of claim 41, wherein the plurality of structures comprisesa plurality of blade structures.
 43. The apparatus of claim 41, whereinthe at least some of the plurality of structures each extend from arespective point generally proximate the longitudinal centerline of thebody generally radially outward toward a gage of the body and include aportion extending longitudinally toward the trailing end of the body.44. The apparatus of claim 43, wherein the at least some of theplurality of structures each carry several of the plurality ofsuperabrasive cutters, and wherein each of the plurality of structuresgenerally encompasses each of the several of the plurality ofsuperabrasive cutters carried thereon with a limited portion of each ofthe several superabrasive cutters exposed by a preselected extentperpendicular from a respective surface proximate each of the severalsuperabrasive cutters so as to control a respective depth-of-cut foreach of the several superabrasive cutters.
 45. The apparatus of claim44, wherein at least a portion of at least one surface of at least oneof the plurality of structures includes a wear-resistant exterior. 46.The apparatus of claim 44, wherein at least one surface is built up witha hard facing on at least a portion thereof substantially surrounding atleast one of the plurality of superabrasive cutters so as to effectivelylimit an amount of exposure of the at least one of the superabrasivecutters.